Cutting 1/8" acrylic sheet

[Monty]

I need to cut a hole in a sheet of 1/8" acrylic approximately 2-7/8" X 7-1/2" in this shape -

I tried using a scroll saw but after it cut, it melted back together and I was unable to get the center out with out the acrylic breaking.
Any suggestions for cutting would be greatly appreciated.

 

[lorbay]

I have used an oval glass cutter in the past.

Lin

 

[Sylvanite]

How big a sheet are you cutting it out of? If it would fit, I'd cut the hole with my laser engraver.

Regards,
Eric

 

[08K.80]

Two methods I have used.
First is my rotozip with a double cut bit, then sand the edge.
The other method and the best in my opinion, my scroll saw. Put a layer of packing tape on both sides of the acrylic and cut as usual. The tape helps lubricate the blade and the kerf doesn't melt back together.
I hope that is helpful for you.:wink:

 

[ed4copies]

keep the area wet (water will work) and insert tiny wood shims behind the cut as you make it.

A scrollsaw with the widest blade possible is better than a sabre saw, cause you can see the back of the blade and insert the shims faster--the water keeps it from melting together.

Edit in: I like Kelly's way better---try it first!!
We typed simultaneously

 

[mrcook4570]

A laser comes in handy for such a task :wink:

 

[Curly]

I would use a hole saw for the ends and saw and file the rest.

 

[redbulldog]

Kelly's way is the better way. When I was in AM school years ago this is what we were taught and I know it works, also there is something in the clear packing tape that helps lubricate the plastic when you are cutting it.

 

[Gary Beasley]

Don't use a reverse style blade to cut it. A Flying Dutchman Polar no.5 is probably the optimum, does great on Corian.

 

[Monty]

Thanks for the suggestions. I'll start with Kelly's suggestion for the packing tape tomorrow.

 

[MesquiteMan]

I would cut out a template from a piece of plywood or MDF, then use double stick tape to stick it to the acrylic and use a template bit or pattern bit in my router to get a perfect cut. No melting to worry with and a much cleaner cut.

 

[PenMan1]

You read my mind, Curtis! A router with a trim bit and bushing is the perfect tool for this task.

 

[Monty]

I would cut out a template from a piece of plywood or MDF, then use double stick tape to stick it to the acrylic and use a template bit or pattern bit in my router to get a perfect cut. No melting to worry with and a much cleaner cut.

That was one of my thoughts also, but I figured it would melt to the bit and make a big mess.

 

[MesquiteMan]

I would cut out a template from a piece of plywood or MDF, then use double stick tape to stick it to the acrylic and use a template bit or pattern bit in my router to get a perfect cut. No melting to worry with and a much cleaner cut.

That was one of my thoughts also, but I figured it would melt to the bit and make a big mess.

It won't melt. I do it almost every day on the chambers I build. No telling how many thousands of feet of routing I have done in acrylic of all different thicknesses.

 

[Monty]

Thanks for the suggestion, Curtis. It worked great. Made a template out of MDF, drilled the ends out with a hole saw and connected them with a saber saw, refines the edges to fit with a wood rasp. Once the hole in the MDF fit, I used double sided sticky tape to hold the acrylic to it and cut it with a pattern bit in my router.
Thanks again to everyone fro their suggestions.

 

[jttheclockman]

Reverse a scrollsaw blade and cut with the backedge.

 

[Dan26]

What Kelly said. Put packing tape over and under the area you are cutting. It's fast and easy. Never once had the acrylic melt back together.