1. Using a Scoring Knife (for thin sheets up to ~3mm)

• Tools Needed: Acrylic scoring knife, straight edge (metal ruler), clamps.

• Steps:

1. Place the sheet on a flat, stable surface.

2. Mark your cut line with a marker.

3. Hold the straight edge firmly and score along the line 5–10 times with the scoring knife.

4. Align the scored line with the edge of your table and clamp securely.

5. Apply downward pressure to snap the sheet cleanly along the score.

2. Using a Circular Saw (for thicker sheets, >3mm)

• Tools Needed: Circular saw or table saw, fine-tooth carbide-tipped blade (60–80 teeth), clamps, safety glasses.

• Steps:

1. Clamp the acrylic sheet securely to avoid vibration.

2. Set blade height just slightly above the sheet thickness.

3. Feed the sheet slowly and steadily through the saw—don’t force it.

4. Use a support board underneath to reduce chipping.

3. Using a Jigsaw (for curves or irregular shapes)

• Tools Needed: Jigsaw with fine-tooth blade designed for plastics.

• Steps:

1. Clamp the sheet to your workbench.

2. Apply painter’s tape over the cut line to minimize chipping.

3. Cut slowly with steady pressure, letting the blade do the work.

4. Sand the edges smooth afterward.

4. Using a Laser Cutter (for precision and complex shapes)

• Tools Needed: CO₂ laser cutter (common in fabrication labs).

• Steps:

1. Place the acrylic sheet flat in the machine.

2. Program your cut path.

3. Use proper exhaust/ventilation—acrylic fumes need to be removed safely.

4. Result: clean, polished edges without sanding.

5. Finishing the Edges

• After cutting, edges may be rough.

• Smooth them with fine-grit sandpaper or a file.

• For a polished look, flame-polish with a propane torch (only if experienced, as overheating can damage the sheet).

Safety Tips

• Always wear safety goggles and a dust mask when cutting.

• Keep protective film on the sheet during cutting to reduce scratches.

• Use slow speeds when cutting with power tools to prevent melting.