How to Cut Plexiglass Into Shapes

The invention of plexiglass has allowed the world to create transparent enclosures or windows without the use of real glass which can be expensive, can break easily, and is tougher to work with. Plexiglass, also known as acrylic glass, is a plastic substance made from primarily acrylic. It is more durable than glass, easier to cut, and easier to replace. However, cutting it can be tough if you have never done it before.

Draw your desired shape on the construction paper with your pencil.

Cut out the shape with your scissors and tape it to your plexiglass sheet using the masking tape. You just need to secure it, so do not tape all the way around it. A few pieces should be fine, depending on the size and complexity of your shape. Try to get one edge touching the edge of your plexiglass sheet. This will make it easier to start cutting.

Trace around your shape with the grease pencil. Remove the construction paper template.

Begin cutting at the edge of your shape that touches the edge of the plexiglass sheet using your coping saw. If you did not or were not able to get an edge to touch, simply begin cutting at the edge of the plexiglass until you reach the edge of your shape. Cut using a downward and upward motion perpendicular to the plane of glass.

Continue cutting around your shape. The small, thin blade of the coping saw will allow you to cut fairly intricate shapes. When finished cutting, remove the shape from the rest of the sheet of plexiglass.

Brush off any shavings or cuttings on your plexiglass shape. File the edges to remove any burrs or cutting mistakes using the Emory board. Your shape is now ready.