posted
I need to cut Polycarbonate sheeting into two, 23" X 84" pieces.
Supplier recommended buying a tri-tooth blade (three teeth curving in different directions) and cutting it on a table-saw, or using a skillsaw.
Curious.... is it possible to use a straight-edge on something this thin and score it, then snap it along the score-line? Or is that impossible with Polycarbonate?
It seems like it will be very difficult to try and man-handle a 4'X8' on a table-saw - - as thin and flexible as it is.
Your time-tested suggestions are greatly appreciated. Thanks!!
-------------------- Todd Gill Outside The Lines Potterville, MI Posts: 7792 | From: Potterville, MI | Registered: Dec 2001
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posted
Plastic cutters are less than $5 at Lowes, Home Depot, and any other good hardware store. Look for them with the box cutters. Couple of swipes with the plastic cutter and just snap it apart.
For heavy plastic score both sides.
[ January 19, 2009, 08:02 AM: Message edited by: Patrick Whatley ]
-------------------- Pat Whatley Montgomery, AL (334) 262-7446 office (334) 324-8465 cell Posts: 1306 | From: Wetumpka, AL USA | Registered: Mar 2001
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posted
Just recently I had to rip two sheets of plexi and used a regular plywood blade in a skill saw. I set the blade to just barely cut through and it went good.
-------------------- Maker of fine signs and other creative stuff. Located at 109 N. Cumberland ave. Harlan, Ky. 40831 606-837-0242 Posts: 4172 | From: Ages-Brookside, Ky. Up the Holler... | Registered: Jul 1999
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Todd, I doubt you'll be able to score and break the lexan.....different animal. It doesn't break like plex. You can, however, cut it with a saber saw (jig saw),hand held circular saw (recommend fine tooth blade). Go slow to keep from grabbing the plastic, or melting it. You're right, the big sheets can be unweildy. Maybe, if you don't already have it in hand, your supplier will cut it at least in half for you.
-------------------- Dale Feicke Grafix 714 East St. Mendenhall, MS 39114
"I can do all things through Christ, who strengthens me." Posts: 2963 | From: Mendenhall, MS | Registered: Apr 1999
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Dale...I scored and broke three 4'x8' sheets of 1/4" lexan into 8"x48" pieces yesterday. That said...getting your supplier to cut it is a whole lot easier.
-------------------- Pat Whatley Montgomery, AL (334) 262-7446 office (334) 324-8465 cell Posts: 1306 | From: Wetumpka, AL USA | Registered: Mar 2001
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posted
I've used the score and snap method too with success...but there is always that "once in a while" thing where the snap doesn't actually follow the score. I'm just more comfortable with a saw.
-------------------- Chapman Sign Studio Temple, Texas chapmanstudio@sbcglobal.net Posts: 6306 | From: Temple, Texas, USA | Registered: Nov 1998
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At the spot where you make a line,(set for the cut) Apply a strip of masking tape so that the cut goes through the center of the tape for the entire length. This will cause the heat from cutting to disipate and keep the blade from gaulding. Sometimes the blade can bind up from heat.
Jack
-------------------- Jack Wills Studio Design Works 1465 E.Hidalgo Circle Nye Beach / Newport, OR Posts: 2914 | From: Rocklin, CA. USA | Registered: Dec 1998
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To whom it may concern, I have a 2" thick piece of blue foam insulation board flat on top of a 4'x8' bench that I lay my plex or poly-carb on to cut it. I use the score and sanp method on thin stock, a saber saw or circular saw on thick stock. Just my 2 pennies worth, Don
-------------------- Donald Miner ABCO Wholesale Neon 1168 Red Hill Creek Dobson, NC Posts: 842 | From: North Carolina | Registered: Apr 2006
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IF - Any shop in your area has one of those 8' long material cutters, that would be my choice. I'm fortunate to work for a company that has one. I don't know the name of this machine, but it will cut (any size up to 8') 1/8 lexan (& other substrates suchas aluminum, dibond, coroplast & alumalite) with very little effort on your part & the results are very acceptable. You must have great respect for this machine. The blade goes in one direction with great force & is not a place for lack of concentration. You mark the piece where you want it cut & hold down & keep fingers well away from clamp which drops down quickly just before blade engages. With proper usage this machine will cleanly cut your lexan alot quicker than it takes to type this message. That would be my first choice. Or, do what Dale Feicke suggests.
-------------------- Bill Cosharek Bill Cosharek Signs N.Huntingdon,Pa
bcosharek@juno.com Posts: 703 | From: N.Huntingdon, Pa, USA | Registered: Dec 1999
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I scored and snapped the first of the two 23" X 84" pieces. I personally found it difficult and imprecise.
Cut the second one on my table saw with masking tape on both sides of where the cut was to be. Cut like butter - perfect.
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This polycarbonate was only 1/8" thick, and even scoring both sides about 3 times each...it was very difficult to snap.....and after snapping the first piece, the second piece only had about 6 inches to snap off the length and because there was no ample extra to bend over - it proved impossible. This is when I decided to not ruin it and went to the table saw. Worked great.
Don't know how anyone could ever score and snap 1/4" polycarbonate??
Probably has something to do with technique I guess. Well, both worked...but in the end, I think the saw is the best way to go.
Thanks for everyone's input. I learned something tonight!
-------------------- Todd Gill Outside The Lines Potterville, MI Posts: 7792 | From: Potterville, MI | Registered: Dec 2001
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I was just comin' in to read what the best 26 ways to cut plastic are . . .
and discovered really only about 3 ways . . .
and also discovered the devastating affects of baba with regard to spelling as well as sentence structure, relativity, and overall lucidity when NO catnip is allegedley involved . . .
ACK- caution! It's highly contagious and affected my spelling too . . . .
posted
Hey Todd, glad you got the material cut OK. I see you used the table saw, with apparently no ill effects. Just as a safety side-note, if anyone else is planning to cut this material...be careful. Depending on the type of saw you have, the blade can catch the material on the backside of the cut, and sling it back at you.
If I have to cut this type of material on the table saw, I set the blade down low, so it just cuts thru the plastic (no more than 1/2 inch in height). I use a piece of pressure treated 2 X 4 or similar about 8 or 10 in. long, start the cut, then set the board down lightly on the top of the blade, and then slide the material under the board. The saw will cut the plastic, but the board will prevent the blade from picking it up and slinging it. I seldom use the table saw for this anymore, but if I have to, that's how I do it. With a saber saw or circular saw, this is not a problem.
Years ago,we used to cut lexan, thin aluminum, PVC and lots of stuff on the table saw...until one day, I was cutting some .080" aluminum, the blade caught the end of the cut, and sent a piece of aluminum about 2 inches wide by 8 inches long sailing over my shoulder, across the shop and it stuck in a drawing board about 3 feet away from where another employee was working. That'll get your attention in a hurry!
I'm sure many may have other, maybe better, suggestions. This worked for me. Be safe.
posted
I am surprised that no one mentioned a hand shear. I have one made by Milwaukee that I cut 1/8" material with. I assume most use this for panels in sign boxes where the edge isn't important. If a true even cut is needed the shear is not my choice.
Boy, a long topic for a seemingly mundane part of the sign shop work day.
-------------------- Wright Signs Wyandotte, Michigan Posts: 2785 | From: Wyandotte, MI USA | Registered: Jan 1999
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Dale - it was a bit 'scary' on the table saw...but, at least I had already 'snapped' the first panel off the 4X8 sheet...so it was easier to handle...I put a table behind the table-saw to help support this wobbly piece, which helped also...but I was very aware and paranoid about the thing shattering and sending a spear of poly through me.
I did have the blade up about 1/4" inch and held the poly on both sides of the saw blade firmly to the table as I slowly fed it through - with the blade guard in place of course!
I forgot to personally thank Pat Whatley - who I called for his instructions on the snap method...as I mentioned, it did work as he said but for some reason it was harder to do than I thought...still, it got me the first piece and it's good info to know.
David - this is a mundane topic for sure. But, heck, it's not something I normally do, so it was kind of a new experience for me. Thanks for muddling through this - and thanks for your advice.
-------------------- Todd Gill Outside The Lines Potterville, MI Posts: 7792 | From: Potterville, MI | Registered: Dec 2001
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