1. Score-and-Snap Method (for thin panels, usually <3 mm)

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

• Steps:

1. Mark the cut line with a pencil or marker.

2. Place a straight edge along the line and score it firmly 5–10 times with the scoring knife.

3. Move the scored line to the edge of a table.

4. Clamp or hold firmly, then snap the panel downward—similar to cutting glass.

• Result: Clean break, ideal for simple straight cuts.

2. Utility Knife (for very thin diffusers)

• Tools Needed: Sharp utility knife, straight edge.

• Steps:

1. Place the panel on a flat surface.

2. Score deeply along your cut line multiple times.

3. Bend gently until it snaps along the line.

• Works for lightweight, brittle diffuser panels but less effective on thicker ones.

3. Jigsaw (for curves or irregular shapes)

• Tools Needed: Jigsaw with a fine-tooth blade for plastic.

• Steps:

1. Clamp the diffuser sheet securely to a workbench.

2. Apply painter’s tape along the cut line to reduce chipping.

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

4. Sand edges smooth after cutting.

• Best For: Circular, angled, or custom shapes.

4. Table Saw or Circular Saw (for thick or large panels)

• Tools Needed: Table saw or circular saw, fine-tooth carbide blade (60–80 teeth).

• Steps:

1. Leave the protective film on the panel.

2. Support the panel fully on the table to prevent vibration.

3. Feed slowly and steadily to avoid melting or chipping.

• Best For: Straight cuts in thicker diffuser sheets.

5. Finishing Edges

• Smooth rough edges with fine-grit sandpaper or a file.

• For polished edges, lightly flame-polish (only if experienced, as overheating can warp the plastic).

Safety Tips

• Wear safety glasses to protect from shards.

• Cut slowly to prevent heat buildup, which can melt or warp plastic.

• Keep protective film on the diffuser until finished to avoid scratches.