How to Cut Polycarbonate Sheeting

In this blog post, we will show you how to cut polycarbonate sheeting the right way. By following these simple steps, you will be able to achieve a clean and professional looking cut.

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Polycarbonate is a strong, durable plastic that can be used in a variety of applications, including storm windows and bullet-proofing material. It is available in both clear and tinted varieties, and can be cut using a few different methods. The best method for cutting polycarbonate will depend on the type of project you are working on and the results you are hoping to achieve.

To get started, you will need to gather a few supplies. You will need a sharp knife or razor blade, a straight edge, and a piece of sandpaper. You will also need to choose the right type of polycarbonate for your project. Clear polycarbonate is best for projects where transparency is key, such as storm windows. Tinted polycarbonate is best for projects where durability and UV protection are more important than transparency, such as greenhouses or shed roofs.

Once you have gathered your supplies and chosen the right type of polycarbonate for your project, you are ready to start cutting. The steps below will show you how to cut polycarbonate sheeting using three different methods – scoring, sawing, and drilling.

1. Place your straight edge along the line where you want to make your cut.
2. Use your knife or razor blade to score the surface of the polycarbonate along the straight edge. Score the surface several times until you have made a deep groove in the material.
3. Bend the polycarbonate sheeting along the scored line until it snaps apart.
4. Use sandpaper to smooth any rough edges along the cut line.


1. Place your straight edge along the line where you want to make your cut.

Tools and Materials Needed

You will need the following tools and materials to cut polycarbonate sheeting:
-Tape measure
-Pencil or pen
-Utility knife or box cutter
-Straight edge or ruler
-Circular saw (optional)
-Jigsaw (optional)

Cutting Polycarbonate Sheeting

Polycarbonate is a strong, tough material with a high resistance to heat and impact. Often used in security and construction applications, it’s also a great material for many DIY projects.

If you need to cut polycarbonate sheeting, there are a few things you need to know to get the best results. Here’s a quick guide on how to cut polycarbonate sheeting:

1. Choose the right saw blade
For best results, use a fine-toothed saw blade designed for cutting plastic. This will minimize chipping and create cleaner, smoother cuts. Avoid using abrasive saw blades as they can damage the polycarbonate sheeting.

2. Score the surface first
Use a sharp utility knife or box cutter to score a line on the surface of the polycarbonate sheeting. This will help the saw blade get started and prevent it from slipping.

3. Use clamps or weights to keep the sheeting in place
Polycarbonate sheeting is flexible, so it’s important to keep it secure while you’re cutting it. Use clamps or weights to hold down the edges of the sheeting so it doesn’t move around while you’re cutting it.

4. Cut slowly and carefully
Slow down and take your time when cutting polycarbonate sheeting. Cutting too quickly can cause the plastic to chip or crack, so go slowly and carefully for best results.

Finishing the Edges

Once you have the basic shape cut out, you will need to finish the edges. The most important thing to remember when cutting polycarbonate is to use a fine-toothed saw blade. A Fine-toothed saw blade will produce a cleaner cut and help to avoid chipping or cracking the material.

If you are using a power saw, be sure to set the blade depth so that it does not cut too deeply into the material. A depth of 1/8″ is usually sufficient. If you are using a hand saw, you may need to make several shallow cuts instead of one deep one.

Once the majority of the cutting is complete, you can use a file or sandpaper to remove any rough edges and ensure that the edge is smooth.

Safety Precautions

Before cutting polycarbonate sheeting, it is important to take some safety precautions. Wearing gloves, eye protection, and a dust mask are all recommended. In addition, it is important to make sure that the area around the cutting surface is clear of flammable materials.

When cutting polycarbonate sheeting, it is important to use a sharp blade. A dull blade will create more friction and heat, which can damage the material. In addition, using a saw with too much teeth can also damage the polycarbonate sheeting. The best way to cut polycarbonate sheeting is to use a circular saw with a fine-toothed blade.