Hey all.....

I finished paint modding my new case for the next build.... but... the next thing to do is cut a big hole in my lid/side panel for a window and then a round hole in the window for a fan...

I got the lid/side panel all taped up reading it for the cut.

But do have a question of the plexiglass/Lexan.......

I purchased a nice piece of Lexan and was wondering what is the best way to cut this so as to give the best finish without shattering.....

I had purchased a Multipurpose Cutting kit for my Dremel (it contains a cone shape thing with a funny looking drill bit that drils upwards... kinda ones that you would use to cut holes in dry wall but it says you can use on plastics) for the attempt of cutting the Lexan.

I have both straight and curve cuts that needs to be done.....


What is your experiences when it comes to cutting Lexan/plexiglass....

Do you know any CNC Millers?? If you want it done like a pro, that's the way to
do it. You must know someone who'll do that as a favour. It'll take no less that half
hour to set and cut. For a friend, i'd do it for free!

Whatever advice you get, first try the cutting method in an area that is non-critical. A totally scrap piece if possible, but if not...for example, if you have a 120mm hole to cut-out, try cutting out a 50-60mm hole in the middle of the 120mm hole.

Different speeds with the same bit will produce different results.

I also recommend supporting the target piece 100% under its entire surface, cutting through both the target piece and the supporting sacrificial piece.

Be sure to cover-tape BOTH sides of the target piece's surface to minimize fractures.

I used a regular power jigsaw. The edges were not presentable but they were all hidden, so it worked for me. The heat from the blade ended up melting the plastic some, but it was fine. You could probably find a way to polish the edges if you need that.

For a hole, you can't beat a hole saw on a drill press. Perfectly round and very quick.

Tools for working on wood should be fine for working on Plexiglass. If you use a hole saw, make sure you use a drill gun with enough torque (heavy duty) and mount a pilot drill in the center. Otherwise, it may end up sliding around causing more damage. But plexi should be much easier than metal, though.

thanks guys for the suggestions........


Absolutely I will be trying different methods on scrap pieces before actually doing the final cut.

I know that if using jig saw or a dremel tool that speed of the bit is important that you dont melt or shatter the cut.... And also the speed at which you push/pull the tool through the material is important at the same time. I also considered using a fine tooth haxsaw blade as well....

If anyone else have experience with working with this stuff, please drop your suggestion into the bucket... much appreciated.