Polycarbonate sheets are incredible and can help you build a greenhouse or a carport, depending on your home needs. However, sometimes you’re going to need to cut them to size to meet your unique needs. What saw you require for this will depend on the shapes and sizes you want. Very thin types of polycarbonate sheeting can be cut with just a utility knife for small, interior jobs. But for precision cuts for exterior glazing you will need a power saw. Here is our guide to cutting polycarbonate sheets.
Tools you will need
A saw – either a circular saw, table saw, or jigsaw
Safety Equipment – gloves and goggles
Glue Clamps (if using a circular saw or jigsaw)
Preparation Work
One of the handy things about polycarbonate is that it doesn’t crack easily and therefore is unlikely to spit shards when cut with a saw. However, with any job you should be advised to wear safety gloves and goggles to protect yourself as much as possible. We also recommend wearing any clothing that is durable and can be thrown away after the job.
Before making any cuts, always make sure that you’ve double checked your measurements. There’s nothing more frustrating than making a mistake and having to get more sheeting. Remember that usually the polycarbonate should be cut so that there is a few millimetres of give between it and the glazing bar to allow for some thermal expansion.Â
Moreover, remember not to remove your polycarbonate sheet’s scratch proof film while cutting. This film should only be fully removed after the sheet has been installed. To create the marking line for cutting, it’s most common to apply masking tape over the film and use that as a surface for markings.Â
Types of saws
Polycarbonate can be cut with several different types of saws. The most common option, good for straight cuts, is the circular saw. The circular saw should be used with clamps and a fine toothed saw for the best results. 4000 revs per minute is the recommended setting for most standard saw sizes. If your saw is larger than 300mm or smaller than 250mm you may have to adjust your RPM. The larger the blade, the less RPM needed.Â
Another good option is the table saw. Again, a fine toothed saw should be used. The table saw will reliably achieve the straight cuts you’re looking for. If you want to minimise the chances of errors on your straight cuts the table saw will likely be your best bet.Â
If you’re looking to cut shapes in polycarbonate, you might consider a jigsaw or a CNC router. A jigsaw is a handheld saw with a reciprocating blade that goes up and down very quickly. However, because of how thin the blade is, you must make the cuts carefully and make sure not to get it stuck. If the blade gets stuck, it might damage the blade, the polycarbonate, or both. Use a fine-toothed blade. Clamps can help secure the sheet as you make your cuts.Â
Cutting polycarbonate with scissors
A pair of scissors may not be able to cut through polycarbonate because it is so stiff and tough. Polycarbonate may, however, be scored and snapped with your scissors if it is thin enough such as 4mm polycarbonate sheets. Make sure to measure out the sheet carefully and give yourself enough space to cut the sheet correctly.
