How to cut plexiglass with a circular saw
In this guide
A circular saw is a good tool for straight cuts in plexiglass (acrylic sheet). The secret is the blade, a clamp-down guide and a steady feed. This guide is part of our saws and cutting hub. For every way to cut acrylic, see how to cut plexiglass.
Most likely problems (and the fix)
| What you see | Why it happens | The fix |
|---|---|---|
| Edge chips or flakes | Sheet vibrates, wrong blade, or too few teeth | Clamp near the line, use a guide board, try a finer TCG blade |
| Edge melts, chips weld back on | Feed too slow, dull blade, blade too hot | Feed faster and steadily, sharp blade, blow air on the cut |
| Saw grabs and jumps | Hook angle too steep, or the sheet sags and pinches | Low-hook TCG blade; support both sides of the line |
| Sheet cracks across | Sheet flexed or bounced | Support it flat; clamp the offcut side too |
| Fine cracks show up days later | Stress from cutting (crazing) | Anneal the part, keep solvents off the edge |
| Cut wanders | No guide | Clamp a straight board or track as a fence |
ACRYLITE's troubleshooting table lists the same causes. For melted edges it says increase the feed rate and cool with air or water. For chipping it says clamp the material, use a guide and use a blade with more teeth.
Can you cut plexiglass with a circular saw?
Yes, in straight lines. ACRYLITE, which makes acrylic sheet, says hand-held circular saws may be used for straight cuts if the sheet is clamped securely so it can't vibrate. It also suggests a board clamped on top of the sheet as a guide.
A circular saw can't cut curves or circles. For a round cut, see how to cut a circle with a jigsaw.
Pick the right blade
This matters more than the saw. ACRYLITE and the Plexiglas guidance on eplastics agree on the basics:
| Blade feature | What to use | Source |
|---|---|---|
| Tip | Carbide-tipped | ACRYLITE |
| Tooth shape | Triple-chip grind (TCG): every other tooth beveled | ACRYLITE, Plexiglas |
| Hook (rake) angle | 0 to 10 degrees positive (Plexiglas: 5 to 10) | ACRYLITE, Plexiglas |
| Clearance angle | 10 to 15 degrees | ACRYLITE |
| Teeth in the cut | 2 to 6, with 3 best | ACRYLITE |
| Use | Acrylic only. Wood and metal dull it | ACRYLITE |
How many teeth on a circular saw blade?
ACRYLITE's chart is for 10-inch and bigger table saw blades. It lists 80 or 100 teeth on a 10-inch blade for sheet from 1/16 to 1/2 inch thick.
To get the same tooth spacing on a smaller blade, we scaled it by size.
A 10-inch, 80-tooth blade has a tooth every 0.39 inch around the rim. On a 7-1/4-inch blade, that spacing works out to about 58 teeth. So look for about 56 to 60 teeth with TCG teeth. Diablo's D0756N, a 7-1/4-inch, 56-tooth blade for non-ferrous metal, has that tooth count and grind.
Check the hook angle on the blade's spec sheet before you buy. ACRYLITE warns that high hook angles cause chipping because the teeth bite too hard. More on this in what blade cuts acrylic.
Planned bench test: 1/8- and 1/4-inch acrylic cut with three blades on the same 7-1/4-inch saw. Results will be added here when the test is done.
Check your blade speed
ACRYLITE says the blade's rim speed should be 6,000 to 14,000 feet per minute for acrylic, and never over 18,000 for carbide. Its formula is: diameter (inches) × rpm × 0.262.
For example, a 7-1/4-inch blade at 5,000 rpm gives about 9,500 feet per minute. Read the no-load rpm on your saw's label.
How to cut plexiglass with a circular saw
1. Mark the line on the film
Leave the protective film on. The Plexiglas guidance says it protects the faces and helps lubricate the cut. Mark the line on the film with a fine marker or tape.
2. Support and clamp the sheet
Lay the sheet on a flat bench with a support board under each side of the line, or on a sheet of rigid foam. Clamp the sheet so it can't move or bounce.
Milwaukee's circular saw manual says to support large panels on both sides near the line. Big sheets sag under their own weight, which pinches the blade.
3. Clamp a guide on top
Clamp a straight board or a saw track on top of the sheet, set so the saw's base rides along it and the blade lands on your line. ACRYLITE says this also cuts vibration.
4. Set the blade depth
Unplug the saw or pull the battery. Set the blade to stick out about 1/8 to 1/4 inch below the sheet. That is the depth Milwaukee gives for circular saws.
5. Cut at a steady pace
- Let the saw reach full speed before the blade touches the sheet.
- Push at a steady, even pace. Don't stop mid-cut. A slow, stop-start feed heats the blade and melts the edge.
- Keep the saw's base flat on the guide.
- Let the blade stop before you lift the saw.
Milwaukee's manual also says to avoid overheating the blade when you cut plastic, so the workpiece doesn't melt. If chips weld behind the blade, speed up the feed a little or blow air on the cut.
6. Clean up the edge
Scrape or sand the saw marks off the edge. Wet sanding through finer grits gives a smooth, frosted edge. Peel the film only when the part is done.
Kickback and safety
Kickback is a sudden jump of the saw back toward you when the blade is pinched, jammed or misaligned. Milwaukee's manual lists ways to prevent it:
- Support the sheet on both sides of the cut so it doesn't sag and pinch the blade.
- Keep the blade straight in the cut. Never twist it.
- Don't back the saw out while the blade spins.
More kickback causes are in our circular saw kickback guide. Acrylic also burns. ACRYLITE calls it a combustible plastic, so keep sparks and flames away.
Thin sheet: score and snap instead
For thin sheet and short straight cuts, you may not need the saw at all.
- ACRYLITE says scribe-and-break works for single sheets under 0.118 inch (3 mm) thick.
- The Plexiglas guidance sets the limit at 0.236 inch (about 6 mm) or less.
Score the line several times with a plastic-cutting knife along a straightedge. Then snap the sheet over the edge of the table. Our fraction to decimal converter turns a sheet thickness like 0.236 inch into a fraction and millimeters.
Other saws for plexiglass
- Table saw: the tool ACRYLITE's blade chart is written for. See table saw vs miter saw vs chop saw and the acrylic FAQ there.
- Trim saw: a small 4-1/2- to 5-3/8-inch circular saw is light and easy to steer on thin sheet. See what is a trim saw.
- Jigsaw or band saw: for curves and circles.
The same support-and-clamp habits help with other sheet goods. See can you cut drywall with a circular saw for dusty boards.
If that didn't work
- Still chipping? Your blade may have too few teeth or too steep a hook. Try a finer TCG blade.
- Still melting? The blade may be dull, or it was used on wood. Keep a blade for acrylic only.
- Cracks near the cut later? That is crazing from stress. ACRYLITE's fix is annealing: heat the part at 175°F (80°C), about 1 hour per millimeter of thickness (2 hours minimum), then cool it slowly.
- Thick sheet (over 1/2 inch)? A table saw or a plastics shop gives a cleaner edge.
When to call a pro
For thick sheet, many identical parts, or polished edges, ask a plastics supplier to cut to size. The acrylic page covers drilling and gluing your parts after the cut.
What you'll need
- Circular saw: Any size; a trim saw is easy to steer on thin sheet
- Carbide triple-chip (TCG) blade: Fine tooth, for plastic or non-ferrous metal; keep it for acrylic only
- Straight board or track: Clamped on top of the sheet as a guide
- Clamps (4 or more): Sheet and guide must not move
- Two support boards or foam board: Under both sides of the cut
- Fine-tip marker or tape: Mark on the film
- Sandpaper (wet/dry) or a scraper: To clean the edge
- Safety glasses and hearing protection: Plastic chips fly
Key takeaways
- A circular saw is fine for straight cuts in acrylic. ACRYLITE says clamp the sheet so it can't vibrate.
- Blade: carbide-tipped, triple-chip teeth, 0 to 10 degrees positive hook, used only on plastic.
- On a 7-1/4-inch saw, about 56 to 60 teeth gives the same tooth spacing as the 10-inch, 80-tooth blade ACRYLITE recommends.
- Too slow a feed melts the edge; vibration and the wrong blade chip it. Air, a steady feed and a sharp blade fix both.
- A circular saw can't cut circles. For round cuts use a jigsaw, band saw or router.
Questions people ask
Can you cut plexiglass with a circular saw?
Yes, for straight cuts. ACRYLITE, an acrylic sheet maker, says hand-held circular saws work if the sheet is clamped down so it can't vibrate. Use a carbide blade with triple-chip teeth and a board clamped on top as a guide.
What blade do you use to cut plexiglass with a circular saw?
A carbide-tipped blade with triple-chip (TCG) teeth and a small positive hook, 0 to 10 degrees. Use it only on plastic. On a 7-1/4-inch saw, 56 to 60 teeth gives about the same tooth spacing as the 10-inch, 80-tooth blade ACRYLITE recommends.
Can I use a wood blade to cut plexiglass?
Only as a last resort on thin sheet. Check its hook angle first: ACRYLITE says high hook angles cause chipping. A blade that has cut wood is also duller, and ACRYLITE says dull blades melt acrylic. A TCG blade kept for plastic cuts cleaner.
How do you cut plexiglass round?
Not with a circular saw. It only cuts straight lines. Use a jigsaw with a fine blade, a band saw, or a router on a circle jig. Our jigsaw circle guide covers each method.
Can you cut plexiglass with a table saw?
Yes. A table saw is the tool ACRYLITE's blade advice is written for. It recommends a 10-inch, 80-tooth carbide blade with triple-chip teeth. For sheet 1/8 to 1/2 inch thick, set the blade about 1/4 inch above the sheet.
Why does plexiglass crack when I cut it?
Most often the sheet vibrates or flexes during the cut. Clamp it flat, support both sides of the line, and use a sharp, fine blade. Stress from cutting can also show up later as fine cracks (crazing). ACRYLITE says annealing the part relieves it.
Sources
- ACRYLITE extruded sheet fabrication brief #3: other methods of cutting (hand-held circular saws, scribe and break, troubleshooting, annealing)
- ACRYLITE knowledge base: what types of circular saw blades are used for cutting acrylic sheet
- eplastics: how to cut Plexiglas acrylic sheet (blade, rake, feed, masking, scribing limit)
- Milwaukee 2530-20 M12 FUEL 5-3/8 in. circular saw operator's manual: kickback, large panels, blade depth, cutting plastic
- Diablo D0756N 7-1/4 in. 56-tooth non-ferrous metal blade
- OSHA 29 CFR 1910.243(a)(1): guards on portable circular saws
Change log: Nov 6, 2026: Rewritten from the 2024 archive post. Removed the wrong advice to pour water on the blade while cutting with a corded saw and the 'Plexiglass vs glass' filler; added ACRYLITE and Plexiglas blade, feed and clamping data, the scribe-and-break limit, a troubleshooting table and kickback safety.
