What do I cut Plexiglass or Acrylic with? And which is easier to work with? - General

I'm trying to figure out how I should cut either of these materials and what is easier to work with, I'm getting a new PC case and I want to replace the ugly side window with a solid clear one.

Table saw. Then burn the edges with a torch. Or buy plexiglass from ace, and they'll cut it to dimensions for you. Almost Any hardware store will cut it and then sell it. Usually something the size of a side for a pc case would be something like $6.00 already cut around here.

Any certain way to cut it with the table saw? Do I go slow, fast, Medium paced? also for making rounded edges should I use a file or can I use the table saw? [editline]20th September 2012[/editline] Also I've got a bandsaw/vertical saw, would that work better? [editline]20th September 2012[/editline] If it helps, I've basically got every form of saw at my disposal.

[QUOTE=Zerokateo;37744510]Any certain way to cut it with the table saw? Do I go slow, fast, Medium paced? also for making rounded edges should I use a file or can I use the table saw? [editline]20th September 2012[/editline] Also I've got a bandsaw/vertical saw, would that work better? [editline]20th September 2012[/editline] If it helps, I've basically got every form of saw at my disposal.[/QUOTE] Bandsaw would be better if you have a wide blade with less than 3/4" spacing between the teeth. Run a piece of wood underneath and leave it in the blade path to block the hole the blade spins into so the plexi or acrylic does not get pulled down on. I recommend not filing it, but actually using a razor to cut the angle if need be. If you file, just go ahead and sand, then just burn the edge to make it clear again.

How long does it take to make the edge clear again with the blowtorch?

I personally just used a circular saw and straight edge to cut a sheet for an animal cage. Just use a new blade that's nice and sharp. I personally didn't clean the edges with the torch, but I'd guess it would only take a quick swipe over the edge with the flame.

You could cheat like me and use a high-powered laser cutter :v: Seriously though, if there's a hackerspace near you, see if they have a large lasercutter that you can use, most hackerspaces have free hours for the public, and if you get certified on it, you can run it whenever you want!

[QUOTE=ewitwins;37748444]You could cheat like me and use a high-powered laser cutter :v: Seriously though, if there's a hackerspace near you, see if they have a large lasercutter that you can use, most hackerspaces have free hours for the public, and if you get certified on it, you can run it whenever you want![/QUOTE] Yeah, I've always used a lasercutter for acrylic, cut's quickly and give a good finish. If you haven't got a local hackerspace or school/college/university you attend that has one, there are things like Ponoko that allow you to order custom bits. You could go further with lasercut and have engravings so when you shine a light through the side it'd illuminate them or whatever.

Welp, I think I'll just use a table saw and then use a jigsaw to make the curved edge. This shit doesn't have to be perfect just has to look nice.

any advice on cutting punchouts? Every tutorial/tool/etc. I've seen is mostly for cutting rectangular sheets, or otherwise cutting from end to end.

[QUOTE=A_flyboy;37769878]any advice on cutting punchouts? Every tutorial/tool/etc. I've seen is mostly for cutting rectangular sheets, or otherwise cutting from end to end.[/QUOTE] That's just usually how you cut plexiglass. You run over it with a razor blade over and over in a straight line to score it then break it off.

[QUOTE=Serj22;37776906]That's just usually how you cut plexiglass. You run over it with a razor blade over and over in a straight line to score it then break it off.[/QUOTE] Be VERRRRY careful, it really sucks trying to score it to break it. Use a saw if you can. Not like a [I]saw[/I] saw, but like a powered saw, something with [B]lots[/B] of teeth.

[QUOTE=ben1066;37748589]... there are things like Ponoko that allow you to order custom bits...[/QUOTE] or like [url]www.LaserCute.com[/url] which accepts ponoko templates but is cheaper and faster

oh great... I'm stuck trying to build a DIY laser cutter then..? =.= fun..... I've got a bunch of heater and PLC equipment here from work, I'm gonna try a "heat it up and cut stencils with a knife" approach first. I'll let you all know how it goes. [b]Update:[/b] I tried it with a little 1/8 in sheet of acrylic, got pretty easy to shape and bend around 325, possible (but difficult) to cut with my little 1 inch blade at 330, but when I hit 340, the acrylic suddenly filled with bubbles... o.0 Not that I care for the current application, but it would be good to figure out how to avoid the bubbles for later :v:

You could make a makeshift hot wire cutter out of nichrome wire (guitar strings would work too). It'd take forever to cut but you'd achieve desired results.

[QUOTE=Zerokateo;37747546]How long does it take to make the edge clear again with the blowtorch?[/QUOTE] Don't blowtorch the ends until you've glued everything, first of all. What you want to do is take the blowtorch about 2 inches away from the edge, then pass it back and forth over the whole length of it until it goes clear. As soon as it's clear, stop. If you hear hissing, back up a little bit and consider giving it a rest for a second.

[QUOTE=CrispexOps;37816099]You could make a makeshift hot wire cutter out of nichrome wire (guitar strings would work too). It'd take forever to cut but you'd achieve desired results.[/QUOTE] Have one, takes about 10 seconds to cut, but that does a linear cut, not a shaped tool. I'm considering how I could make a heated knife of some kind... I'm trying to etch a hole in it to mount the ac socket (taken from the back of a PC PSU), so not exactly a place for my 4 foot nichrome... haha... any thoughts? [QUOTE=Mr. Smartass;37816619]Don't blowtorch the ends until you've glued everything, first of all. What you want to do is take the blowtorch about 2 inches away from the edge, then pass it back and forth over the whole length of it until it goes clear. As soon as it's clear, stop. If you hear hissing, back up a little bit and consider giving it a rest for a second.[/QUOTE] Thanks, I found out about this process the other day, but when I tested it, I totally lit the piece on fire, which just causes the edges to super fray v:v:v I'll try it your instructions tmr.

At a place I used to work, we used a jigsaw. So long you get a fine cutting blade, with a lot of teeth and take your time you should be fine. Also if you use a saw, you want to take your time. The plastic likes to heat up and stick to the blade. For the edge of it do as the others have said.

I've noticed that... I use a saw for the larger knockouts, but for smaller cuts like this power port are more difficult. Also it would be great to be able to fab these things using heat, its cleaner. ><