How to Cut Lexan Polycarbonate Sheet

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I recently needed to cut a small piece

of point zero nine three-inch that's

three thirty-seconds of an inch thick

piece of lexan for a DIY cat door

don't confuse lexan that's the brand

name for polycarbonate with acrylic

Plexiglas lexan is over 200 times

stronger than glass and acrylic

Plexiglas is only four to eight times

stronger than glass this is a piece of

polycarbonate roofing material

it's about 1/32 of an inch thick it's

easy to cut through this thickness with

a pair of aviation shears for a longer

cut the material starts to get in the

way it becomes more difficult it's more

difficult to cut through the 332nd inch


for comparison purposes here's the 132nd

thick inch piece and the 332nd inch

piece of lexan I'll use a dremel tool

I'll give a metal cutting wheel a try


let's say on scratches easily if it has

a protective plastic sheet on the

surface do not remove the sheet until

all work is completed

that didn't do too badly the bottom edge

is a little rough I suppose you could

prevent that by clamping another piece

of material on the underside and then

cut it the best way I found to cut it

without using a saw is to use a new

utility knife blade clamp a straight

edge on top of the piece that you're

cutting onto a solid surface then cut

with utility knife and you'll have to do

this multiple times maybe until it's

about halfway cut through the thickness

the blades don't quickly have some

extras on hand I clamp it down with a

straight edge along the scored line

it'll get a pretty clean cut that way if

you don't clamp the piece down and a

straight edge to it it's likely that you

won't score in the same track you'll get

an even break I hope you found this

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