How to Cut Polycarbonate Sheet - ExcelitePlas

How to Cut Polycarbonate Sheet

  • How to cut polycarbonate sheet?
  • What is the best tool to cut polycarbonate roofing sheets?
  • What's the difference between Acrylic sheet cutting and Polycarbonate sheet cutting?

Find all the answers in this blog. 

Cutting Polycarbonate sheets can be daunting, there's a misconception that plastic sheets crack easily when cut, but this is may happen for acrylic sheet or PetG sheet. Excelite polycarbonate sheets, including Solid polycarbonate sheet, Multiwall sheet, and Twinwall Sheets, and polycarbonate corrugated sheets are much easier to cut. 

Polycarbonate Sheets, available in thicknesses from 1mm to 35mm, are popular for DIY and trade projects due to their ease of cutting.

For polycarbonate Roofing sheet, Before cutting, calculate rafter spacings and allow for Aluminium H joiners and fixings, ensuring a small gap for expansion and contraction.

Whether you're roofing a pergola, gazebo, or greenhouse, the cutting method is straightforward. Need a polycarbonate roof kit? Contact our team for the best materials and advice.

What Tool Do I need to Cut Polycarbonate sheet?

To cut polycarbonate sheets and Polycarbonate roofing sheets, you can use a variety of tools depending on the thickness and type of cut you need. Here are some common tools

  • Utility Knife/Scissors: For thin polycarbonate sheets (up to about 3mm), or polycarbonate corrugated sheet a sharp utility knife or scissors can be used. Score the sheet several times along a straight edge until you can snap it cleanly. But don't recommend.  It's hard to cut it straight and neat.
  • Fine-Toothed Circular Saw: A circular saw with a fine-toothed blade (60 teeth recommended) is ideal. Blades designed for plastic or non-ferrous metals work best. Ensure the saw is stable and cut slowly to avoid melting the material. Circular saw can use to cut polycarbonate sheet thickness from 1mm-35mm. It's also suitable to cut Acrylic sheet.
  • Jigsaw: A jigsaw fitted with a fine-toothed blade can handle intricate cuts or curves. Use a slow to medium speed to prevent the polycarbonate from chipping or cracking.
  • Table Saw: For precise, straight cuts on thicker sheets, a table saw with a fine-toothed blade can be effective. Again, use a blade designed for cutting plastics and work slowly to maintain a clean cut.
  • Band Saw: A band saw with a fine-toothed blade can be used to cut polycarbonate sheet for both straight and curved cuts, particularly on thicker polycarbonate sheets.
  • CNC Routing:  If you need to cut complex shapes and designs with high precision and consistency, CNC routing is recommended. It ensures a high-quality edge finish and is highly efficient for large-scale production.
  • Laser Cutting:  Laser cutting is highly precise and ideal for intricate designs in polycarbonate sheets, offering smooth, clean edges without physical tool wear. However, it works best for thinner sheets (up to 6mm) due to the risk of melting and discoloration. Proper settings and ventilation are crucial to avoid heat damage and toxic fumes. For thicker sheets, CNC routing may be more suitable.

What is the difference between Cutting Acrylic sheet and Cutting polycarbonate sheet?

Cutting polycarbonate and acrylic sheets involves different considerations due to their distinct properties. Here are the key differences:

Polycarbonate sheeting

  1. Material Properties: Polycarbonate panel is more flexible, impact-resistant, and less prone to cracking compared to acrylic sheet.
  2. Cutting Tools: Polycarbonate can be cut using a utility knife for thin sheets, fine-toothed saws, jigsaws, table saws, or CNC routers for thicker sheets. It can also be laser-cut, but with caution due to potential melting and discoloration.
  3. Cutting Process: Cutting polycarbonate requires slower speeds and lower power settings to prevent melting. It's less likely to crack but can deform if too much heat is applied.
  4. Applications: Used in applications requiring durability and impact resistance, such as in safety glazing and outdoor structures.

Acrylic sheeting

  1. Material Properties: Acrylic panel is more rigid and has a higher clarity than polycarbonate but is more brittle and prone to cracking.
  2. Cutting Tools: Acrylic can be cut with a laser cutter, which is often preferred for its clean edges and precision. It can also be cut with circular saws, but there is a higher risk of chipping and cracking than polycarbonate sheet.
  3. Cutting Process: Acrylic can be laser cut easily without the melting issues common with polycarbonate. It requires careful handling to prevent cracks during manual cutting.
  4. Applications: Preferred in applications where clarity and aesthetic appearance are important, such as in displays and decorative items.

Are solid polycarbonate sheets cut the same way as Multiwall or Twinwall polycarbonate sheets and corrugated sheet?

Cutting solid polycarbonate sheets follows a similar method to cutting Multiwall and Twinwall Polycarbonate sheets, but there are some key differences. You need to cut more slowly, especially with thicker solid sheets, to prevent the saw dust from clogging the saw gap. This helps achieve a cleaner cut and reduces the risk of overheating or melting the material.

What is the best tool to cut polycarbonate roofing sheets with?


A circular saw with a fine blade and a track is the best option for cutting plastic roof sheets and is easy for cutting longer lengths if you have a long enough circular saw guide rail.


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