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Discussion Starter #1
What in the world do you use to cut plexi-glass? I used a scroll saw and if I stop the heat melts the plexi back on itself. I have broke 2 blades trying this method. Then tried a jig saw, same thing, melts the plexi-glass and you can only do real small pieces at a time as I need to break the piece off fast before it completly hardens again. Please tell me there's a easier way.
 

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A table saw works too if you have one or a hacksaw (and alot of elbow grease). Be sure to use the proper glue to bond it when your making your prop.
 

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I agree with Jeff. A hardware store has a blade for their glass cutter that will do plexiglass. I'd just buy it or take it there.
 

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In junior high, we used a band saw to cut plexiglass and a drill to make holes in it. We also used some kind of sign making tool that worked like an upside down router to carve letters into the plexiglass. Maybe using a different blade for the jigsaw might help. Maybe a finer toothed, thinner blade. And keep the saw moving, don't let it sit in one place....or y'know....get the guy at the store cut it. That might be a better idea.
 

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Table saw for sraight cuts just be sure to protect it as you slide it over the table. I have also used a roto zip, jig saw, circular saw, and when a templet was available (as well as time and patience) a razor blade. However, what I found to be the trick was to cut heavy(aliitle bigger than what you want) then to sand and or file the edges smooth.
 

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They make plexi cutting blades. Check Lowes or something. You need to score it and snap it. if you're careful, you can do it with a good straight edge and a fresh blade in a utility knife. you'll just need to score, and re score it multiple times, and then snap it along the score line.
 

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Discussion Starter #8
Thanks guys, I was getting fustrated and decided I'd ask the resident experts here. Although I'd love to get the hardware store to cut they said they only can do 1 straight cut for me and I'm cutting at least 3 different pieces that are not simple cuts. I'll try some other tools tomorrow, just gotta find them and see what will work. I swear, ever day something different gets in the way of my prop building process.
 
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Trust me, we all understand that it can be frustrating sometimes, but never, never, never give up. Everyone goes through it all the time. Besides, with this type of support staff, we won't let you. LOL
 

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The trick to cutting plexi with a scroll saw is to dial down the speed. If yours is adjustable, lower the speed so that the heat build up is minimized.

If the scroll saw isn't an option, use a band saw if you have one. The blade on it will carry the plastic away and not allow a melted build up.
 

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I used a saber saw and a general use blade and it worked perfectly... but I made my skull servo mounts outta about 1/4-1/3" plexi... worked great... 3 done so far... now just need servos and programming... lol:jol:
 

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I use a spiral saw (like a rotozip) to cut mine... but it helps to use a guide fence, otherwise the bit tries to walk around through the plexi and leave a real ragged cut.
 

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When cutting plastic slow speed, high feed, and a medium coarse blade are your friends. I machine all kinds of plastics at my job (plexi, nylon, uhmw, delrin). Like it was said before, a good jig saw with a medium coarse blade dialed down in speed will work great. I use a table saw and/or circular saw for straight cuts when not using the 4'x10' cnc router at work.
 
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