HOW TO CUT A POLYCARBONATE SHEET

Polycarbonate Sheets:

Polycarbonate sheets are strong, tough corrugated and lightweight thermoplastic sheets having wide applications in various industries. They are highly resistant to heat and electricity.

Without getting them broken, they can be molded or formed and deformed easily.

Why would you need to cut a polycarbonate sheet?

Polycarbonate sheets are widely used in the construction of noise barrier walls, glazing, dome lights, etc. since they can provide insulation from electricity and sound. Protective windshields, corrective lenses, medical equipment, bottles for liquids, optical disks, lightweight cases for luggage, electronic items like toys, computer cases also find the usage of polycarbonate sheets. Durable and lightweight items can be made using polycarbonate sheets. Knowing how to cut polycarbonate sheets will let you make durable creative and innovative things with ease.

So, one in the construction industry or using it to doing it yourself (DIY) self crafting purposes may need to cut a polycarbonate sheet to be able to put it to utilization.

We will now learn how to do them so. Polycarbonate sheets come in a varied range of thickness. Depending upon the same, materials and methods used as the cutting tools may vary.

Materials needed to cut a polycarbonate sheet:

•    Hand shears

•    Mechanical saw (circular saw, vertical band saw, hand-held jigsaw)

•    fine-toothed blade

•    Duct tape

•    Marker

•    Measuring tape

•    Sharp utility knife

•    C-clamps

Step by step method to cut a thin polycarbonate sheet:

1. Paper thin polycarbonate sheets can be cut in a jiffy.

•    Fix the sheet onto the flat surface using duct tape. The sheet should not be stretched. It can alter the line of cut.

•    Measure the cut and mark it clearly with the marker.

•    Outline the cut using duct tape.

•    Since the sheet is paper thin, you can cut it with a sharp utility knife easily. Now, you have the desired cut out from the sheet.

2. If the sheet you desire to cut is a bit thick but less than 0.125 inches equivalent to 0.3175 cm, you may need a hand shear to cut the sheet.

•    The protective plastic cover of the sheet should not be tampered with. This is necessary to protect the sheet from any mechanical damage that may occur to the sheet while cutting.

•    Fix the sheet onto a flat surface using 2 x 4s to provide it support on both sides of the cut.

•    Identify, measure and mark the cuts clearly using a marker. Mark edges on both the sides for straight cuts. Then join the marks with a small straight line.

•    For the straight cut, a circular saw is used. Install the fine-toothed saw blade in the saw. The approximate speed of the saw should be 3400 RPM. If the diameter of the blade is between 10 to 14 inches, it should be in the range of 60 to 80 teeth.

•    Initiate the saw and cut it. Do not stop the saw in the middle of the action or until the cut is finished. The blade will do its work. You need not force the saw. It may crack the sheet.

3. If curved cuts are desired in the sheet, you will need the hand-held jig saw.

•    Fix the sheet onto the flat surface in a similar manner as discussed above using 2 x 4s for supporting the sheet.

•    Identify, measure and mark the cut areas on the sheet.

•    Install the fine-toothed blade in the saw in a manner so as to have a minimum of 10 teeth per inch.

•    The saw speed should be adjusted at 12000 strokes in a minute.

•    Initiate the saw and cut it. Remember not to stop the saw until the cut is finished. You may not want to crack the sheet.

4. Curved cuts can also be performed using the vertical band saw. This saw is used for larger sheets, cut on which cannot be performed on a normal small sized saw table.

•    The sheet will need to be supported by the side table supports. Fix the sheet properly and ensure that it is well supported.

•    Identify, measure and mark the desired cuts.

•    Install the fine-toothed blade that has approximately 10 teeth per inch in the saw.

•    Observe the speed of the saw and set it at a rate of not more than 7500 feet per minute. You can use the operation manual instructions for setting the speed.

•    With a vertical band saw, the sheet has to be moved in the blade at a constant speed. Do not push in the sheet too fast. Since the sheet is a thermoplastic, moving in the blade at a faster pace can heat the polycarbonate earlier than required. And this heated resin will melt. The molten fluid can be accumulated in the teeth of the blade and it might break.

5. For yet thicker polycarbonate sheets, use the circular saw. The thickness of the sheet can be more than 0.125 inches but not more than 0.50 inches.

6. For performing cuts on the polycarbonate sheets which are thicker than 0.50 inches, i.e. 1.27 cm in thickness, you may use a table saw.

•    Identify, measure and mark the desired cut.

•    You may use a duct-tape to frame the marks.

•    Install the fine-toothed saw blade as per the kind of cut desired.

•    You will have to manually move the sheet into the saw. Remember to keep your speed steady. Neither increase the speed nor decrease it. Keep it constant to avoid the plastic sheet from getting cracked or the saw blade getting broken.

•    Do not stop until the cut is complete.

You may use some light machine oil to lubricate the blades for smooth functioning. Moreover, it is a good tip in the maintenance of the saw blades.

While performing cuts in the polycarbonate sheets, a considerable amount of dust is generated. It is advisable to use the protective gears to avoid inhaling the dust which may be harmful to health.