Feed the work slowly and smoothly. Lubricate the blade with soap or beeswax to minimize gumming from the masking adhesive. Be sure the saw is up to full speed before beginning the cut. Water cooling the blade is suggested for thicknesses over 1/4", especially if edge cementing will be performed.
Use metal or plastic cutting blades. The blades you use to cut acrylic should never be used for any other material. Cut at high speed and be sure the saw is at full speed before beginning the cut.
Good results are possible, but very difficult. Be sure the acrylic is clamped to prevent flexing. Flexing at the cut may cause cracking.
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Routers and shapers Use single fluted bits for inside circle routing and double fluted bits for edge routing. At the high speeds at which routers operate it is critical to avoid all vibration. Even small vibrations can cause crazing and fractures during routing. Drilling For best results, use drill bits designed specifically for acrylic. Regular twist drills can be used, but need modification to keep the blade from grabbing and fracturing the plastic. Modify the bit by grinding small flats onto both cutting edges, so the bit cuts with a scraping action. If the drill is correctly sharpened and operated at the correct speed, two continuous spiral ribbons will emerge from the hole. Finishing Acrylic Scraping The first step in getting a finished edge is scraping. The back of a hacksaw blade is perfect for scraping. Simply draw the corner of the square edge of the blade along the edge of the acrylic. Filing A 10 to 12 inch smooth cut file is recommended for filing edges and removing tool marks. File only in one direction. Keep the teeth flat on the surface, but let the file slide at an angle to avoid putting grooves in the work. Sanding If necessary, start with 120 grit sandpaper, used dry. Then switch to a 220 grit paper, dry. Finish with a 400 grit wet/dry paper, used wet. Grits as fine as 600 may be used. Always use a wooden or rubber sanding block. When removing scratches be sure to sand an area larger than the scratch. Sand with a circular motion, and use a light touch and plenty of water with wet/dry papers.