How to Cut Plexiglass Without Chipping

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when I make picture frames I like to use

ordinary sheet acrylic or polycarbonate

that you can find at the Home Center for

the glass it's pretty affordable and you

can cut it to any size you need at the

table saw but there's a couple of

challenges to doing that for one this

thin material will want to flutter next

to the blade when you cut it and that

can be a safety hazard and often times

the blade will chip out the corner at

the back of the cut where the material

is the weakest well here's a simple and

safe method that I use for cutting

Plexiglas at the table saw to keep these

problems from happening for this job I

use a crosscut sled to give the

plexiglass as much support as I can and

help keep from scratching it as I push

it across the saw table I clamp a stop

block to the fence of my crosscut sled

both to dimension the piece and to keep

it from shifting as I'm cutting it then

I take a piece of rigid scrap plywood

that's at least as big as the plexiglass

I'm cutting and I set that down over the

top and I use a push block to hold

everything down and to keep my hand

safely out of harm's way now to prevent

chipping a corner I start by just

cutting partway into the sheet then I

pull it back and turn the saw off next

with the partial cut made I'll flip my

plexiglass over so this cut edge is

against the back of my crosscut sled and

I'll do the same thing with the plywood

flipping it over then I'll go ahead and

make a cut all the way across the piece

with this two-step cutting method you're

never finishing the cut at a corner

where the plexiglass is most likely to

chip and that plywood eliminates all the

fluttering and what you're left with is

a smooth clean cut from edge to edge

with no splintering and chipping every

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