Sawing polycarbonate sheet is relatively easy compared to cutting acrylic. Polycarbonate is very impact-resistant and much tougher so that cutting a polycarbonate sheet is achievable even for the less experienced do-it-yourselfer. We are happy to give you some tips for sawing polycarbonate with a circular saw and jigsaw and if you equip yourself with the necessary personal protective equipment, then little can go wrong.

Preparations for sawing

When cutting polycarbonate, leave the protective film and do not mark the saw line on the foil. Stick masking tape on the place where the saw line should be and mark the line here.

Cut polycarbonate painterly tape

Cutting polycarbonate sheet with a circular saw

A circular saw is the best tool to use when cutting larger lengths of polycarbonate. Due to the properties of the material, polycarbonate will not crack or crumble around the cut. Polycarbonate is also quite insensitive to heat generation, regardless of the cutting speed and the speed of the saw. Nevertheless, it is important to choose the right circular saw and to keep an eye on the speed and throughput, as only then will you get the best cut.

Take a saw blade with fine teeth, with a standard size saw blade (250 – 300 millimetres); we recommend a speed of 4,000 revolutions per minute. With this combination, you get a nice, smooth cut. The saw determines the cutting speed and thus the throughput speed, which is around 8 metres per minute, or 10 to 15 centimetres per second.

Cut polycarbonate circular saw

Cut polycarbonate with a jigsaw

You can also cut fine polycarbonate sheets with a jigsaw. Because of a tight cut, it is important that the sheet is pressed firmly during cutting, it should not move up and down with the saw blade. We recommend that you secure the sheet along the cut with an offcut of wood and glue clamps.

Take a saw blade with fine teeth, for example, a saw blade for non-ferrous metals. Set the saw to medium speed and allow it to move slowly through the sheet. Do not exert too much pressure on the saw, but allow it to do the work and determine the feed speed. Please note that the sole of the jigsaw will stay flat on the polycarbonate sheet.

Cut polycarbonate jigsaw

Requirements for cutting polycarbonate

• Circular saw or table saw with adjustable speed (recommended speed 4,000 rpm)
• Saw blade with fine teeth
• Sheet material or wood slats for support
• Glue clamps (to keep the plate pressed against the worktop)
• Jigsaw with adjustable speed
• Saw blade for non-ferrous metal
• Masking tape for marking_