Tools & Materials Needed

• Cutting Tools (choose one):
  • Laser cutter (professional, precise)
  • Table saw with fine-tooth blade (for straight cuts)
  • Jigsaw with acrylic-specific blade (for curves)
  • Hand saw (for small projects)
  • Scoring tool + straightedge (for thin acrylic)
• Safety Gear:
  • Safety goggles
  • Dust mask (for cutting)
  • Gloves (to handle sharp edges)
• Accessories:
  • Clamps (to secure the acrylic)
  • Pencil + ruler/straightedge (for marking)
  • Sandpaper (120–400 grit) or deburring tool (for edge finishing)

Step 1: Measure & Mark the Cut

1. Use a ruler and pencil to draw a straight line where you want to cut.
2. For curves or complex shapes, trace a template onto the acrylic with a marker.
3. Double-check measurements to avoid mistakes!

Step 2: Secure the Acrylic

• Clamp the acrylic sheet firmly to a workbench to prevent movement during cutting.
• For table saws or jigsaws, ensure the sheet is stable and aligned with the tool’s path.

Step 3: Choose Your Cutting Method

Option A: Laser Cutter (Best for Precision)

1. Load the acrylic into the laser cutter.
2. Set the power and speed settings (typically 20–30% power for 1/8" acrylic).
3. Let the machine do the work! Laser cutting leaves smooth edges but may produce slight residue.

Option B: Table Saw

1. Install a fine-tooth blade (60–80 teeth) and adjust the blade height to slightly above the acrylic thickness.
2. Run the saw slowly and steadily, guiding the acrylic along the fence.
3. Safety Tip: Keep hands at least 6 inches away from the blade.

Option C: Jigsaw

1. Attach a blade designed for plastics (e.g., Bosch T118B).
2. Start cutting along the marked line, applying gentle pressure.
3. For tight curves, make small relief cuts first.

Option D: Hand Saw

1. Use a fine-tooth hacksaw or coping saw.
2. Score the line repeatedly while applying light pressure.
3. Snap the acrylic along the scored line for a clean break (works best on thin sheets).

Step 4: Finish the Edges

• Use sandpaper (start with 120 grit, then 400 grit) to smooth rough edges.
• For a polished look, apply a flame-polishing tool or acrylic edge-burnisher (adult supervision required).

Safety Tips

1. Always wear safety gear to protect against dust and debris.
2. Avoid cutting acrylic near open flames (it’s flammable).
3. Keep children away from tools.
4. Ventilate the area to reduce fumes from cutting.

Common Mistakes to Avoid

• Rushing: Slow, steady cuts prevent cracks.
• Using the Wrong Blade: Dull or inappropriate blades cause rough edges.
• Forgetting to Clamp: Loose acrylic can lead to uneven cuts or accidents.