Cutting HPL: how to do it

Cutting HPL sheets, also known as composite panels, is comparable to sawing hardwood. This is because HPL is composed of natural fibres that are protected by a hard EBC top layer of synthetic resin. In this blog, we explain the best way to cut HPL with a jigsaw or circular saw.

Requirements for cutting HPL:

  • Circular saw blade with alternating or trapezoidal teeth
  • Jigsaw with variable speed and adjustable pendulum position
  • Glue clamps or locking pliers
  • Hacksaw blade (for non-ferrous metals) for jigsaw
  • Masking tape
  • A pen or pencil
  • Safety glasses
  • Baseboard into which the drill can run

Before you start cutting HPL…

When you order HPL panels, you’ll find that most of them come with a protective film that prevents damage during storage and transport. But it’s also handy to leave this foil in place if you’re going to cut HPL panels, as it prevents it from being damaged during cutting. We also advise marking the cutting line on masking tape before you start sawing.

Selecting the right HPL cutting blade

To cut HPL, you need a saw blade with fine teeth so that you get a tight cut. We recommend choosing a metal saw that can also cut iron and aluminium. For a circular saw, it’s best to use an alternating-tooth, or trapezoidal flat-tooth saw blade.

Cutting hpl

Cutting HPL sheet with a jigsaw

When sawing HPL with a jigsaw, always set the pendulum position at position 1. If you set it higher, this could cause cracks in the finish. When you use positions 2 and 3, the saw blade makes an up and down movement, namely a forward stroke. To cut HPL sheet cleanly, let the saw teeth set on the side with the printed layer so that the jigsaw sole runs over the reverse of the panel. When cutting, choose a medium cutting speed and make sure that the sole of the jigsaw is completely flush with the sheet. Let the blade do the work and push the jigsaw lightly along the cutting line.

Sawing HPL panels with a circular saw

If you prefer to saw your HPL panels with a circular saw, the same rule as above applies: let the saw teeth enter the side with the printed layer. Make sure the cutting depth is three to four times the panel thickness. If you have a circular saw without splinter protection, we recommend taping the cutting line with thick masking tape. We recommend that you always wear safety glasses when you’re cutting HPL.

HPL sheets custom-cut to size

Would you prefer not to cut HPL sheets yourself? Order your HPL panels directly in our webshop, and we will cut them to size for you free of charge. You’ll receive your order as soon as possible. If you have any questions about this blog or our products, please don’t hesitate to contact us.