Acrylic sheet—also called PMMA or plexiglass—is a durable, lightweight alternative to glass that can be easily shaped and customized.
One of the most common fabrication questions is: can you cut acrylic sheet with a jigsaw?
The answer is yes. A jigsaw is one of the most practical and accessible tools for cutting acrylic, provided it’s used with the correct blade type, speed, and handling technique.
At KUNXIN Plastics, we specialize in custom acrylic sheet cutting, CNC fabrication, and finishing services for clients worldwide, and we often guide buyers on safe on-site processing methods.
A jigsaw provides several advantages when working with acrylic:
Versatility: It can cut straight, curved, and irregular shapes.
Accessibility: Jigsaws are widely available, inexpensive, and easy to control.
Precision: With proper setup, jigsaws can deliver clean, chip-free edges.
Speed: Faster than hand scoring, suitable for medium-thickness panels (2 – 10 mm).
However, acrylic behaves differently from wood or metal—it is rigid but brittle. Using the wrong technique can cause melting, chipping, or cracking. The key is to control heat and vibration.
Selecting the correct jigsaw blade is the most important step.
| Blade Feature | Recommendation | Reason |
|---|---|---|
| Tooth Type | Fine-tooth, straight-cut metal blade | Prevents chipping |
| Tooth Count | 10–14 TPI (teeth per inch) | Smooth cut on hard plastics |
| Material | High-Speed Steel (HSS) or Bi-metal | Resists heat buildup |
| Edge | Ground or milled | Produces a clean finish |
Avoid aggressive wood-cutting blades—they remove too much material and generate excessive vibration.
Use a soft pencil or masking tape to mark your cutting line.
Clamp the acrylic firmly on a flat workbench, with the cutting section fully supported to prevent flexing.
Keep the protective film on both sides to prevent scratches.
If the sheet lacks film, cover it with masking tape.
Set your jigsaw to a medium speed (around 1,500 – 2,000 strokes/min) and low orbital action.
Too much speed can melt the acrylic, while too slow can cause cracking.
Start Slowly
Position the blade at the sheet’s edge, start at low speed, and allow the blade to reach full motion before entering the material.
Steady Motion
Guide the jigsaw gently and evenly along the line. Do not force the cut—let the blade work naturally.
Avoid Overheating
Pause periodically on thick sheets to allow cooling. You can also use compressed air or light water mist to reduce friction heat.
Finish the Edge
After cutting, remove burrs using fine-grit sandpaper or a deburring tool.
For optical edges, polish with flame polishing or buffing wheels—services we provide at KUNXIN Plastics.
| Safety Concern | Best Practice |
|---|---|
| Cracking | Support the sheet evenly; avoid bending during cutting |
| Melting | Use low-medium speed; avoid dull blades |
| Blade Binding | Keep steady feed pressure; clear debris |
| Dust and Chips | Wear eye protection and a dust mask |
| Noise and Vibration | Use clamps and rubber padding to damp vibration |
Following these guidelines ensures a smooth, professional-looking cut with minimal risk.
If your project requires mass production or tight tolerances, KUNXIN Plastics offers advanced options beyond manual jigsaw cutting:
CNC Laser Cutting – produces flawless edges and precise curves.
CNC Router Milling – ideal for thick acrylic plates or mechanical parts.
Saw Cutting Lines – fast and efficient for large-volume sheet trimming.
Heat Bending & Forming – enables 3D shapes for displays, signage, and covers.
Each process is performed in our Jiangmen, Guangdong facility using 100 % virgin PMMA for high optical clarity.
Using a high-speed setting: Causes melting and rough edges.
Pressing too hard: Leads to cracking or kickback.
Ignoring support under the sheet: Can result in fractures.
Cutting without cooling: Increases blade friction and warping.
Skipping edge finishing: Leaves sharp or frosted surfaces.
With proper technique, a jigsaw can deliver factory-level precision for prototypes and small production runs.
Q1: What thickness of acrylic can I cut with a jigsaw?
Typically, up to 10 mm is manageable. For thicker sheets, slower feed speed or CNC cutting is recommended.
Q2: Can I cut curves with a jigsaw?
Yes. Use a narrow blade (6 mm or less) to achieve smooth, tight curves.
Q3: How do I prevent melting?
Lower the speed, use sharp blades, and allow airflow or short cooling breaks.
Q4: Can extruded and cast acrylic both be cut with a jigsaw?
Yes. However, cast acrylic gives cleaner edges and less melting than extruded acrylic.
Q5: Do you offer pre-cut or customized acrylic panels?
Absolutely. KUNXIN Plastics provides custom-sized acrylic sheets, laser cutting, and OEM/ODM finishing services for lighting, signage, and architectural clients.
Yes—you can cut acrylic sheet with a jigsaw safely and accurately when following proper methods.
By choosing the right blade, controlling speed, and supporting the material, even complex cuts can be achieved without cracking or melting.
For commercial or high-volume needs, KUNXIN Plastics offers professional CNC, laser, and precision jigsaw cutting services, ensuring every panel meets optical and dimensional standards.
Explore our full range of optical and Decorative Acrylic Sheets at www.kunxinplastics.com and contact our team for expert fabrication support.
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