5 Best Ways to Cut Plastic – Which Tool to Use? – Reviews & Top Picks in 2023
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Cutting plastic is often more difficult than cutting other materials. It can break, bend, or crack depending on the thickness of the plastic and the strain you put on it while cutting. Furthermore, plastic can do a number on your cutting tools if you aren’t careful or bring the wrong tool to the job. Most cutting tools and blades are designed for wood or metal, but plastic is often overlooked. However, we’ll discuss the best ways to cut plastic and which tools to use.
Comparison of Our Favorite Picks for 2023
| Rating | Image | Product | Details | |
|---|---|---|---|---|
Best for Thin Plastic
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Milwaukee 48-22-1903 Fastback 3 Utility Knife with 4 Blade Storage |
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CHECK PRICE |
Best for Medium Thickness
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WEN 3939 2.8-Amp 9″ Benchtop Band Saw |
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CHECK PRICE |
Best for Thick Plastic
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Rockwell RK3440K Versacut |
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CHECK PRICE |
| Best for Curved & Complex Cuts |
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Bosch JS470E Jigsaw |
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CHECK PRICE |
| Best for Large Projects |
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Grizzly Industrial 10” Cabinet Table Saw |
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CHECK PRICE |
Preparing to Cut Plastic
Regardless of your tool, you’ll need to prepare your workbench or cutting space to cut through plastic correctly. You never want to cut plastic while some is hanging off your cutting space. You should try to place the entire piece of plastic you want to cut on a flat surface. This prevents it from bending and turning brittle.
Next, be sure that the blade is well-sharpened and heated beforehand. Why heat the blade? Many plastic sheets or pieces will catch fire or melt if you don’t heat the blade and cut through the plastic quickly beforehand.
This is more common with cheaper or thin plastics, but regardless, non-heated blades are likely to melt your plastic sheet or other material rather than cut through it. By heating the blade, you cut so quickly that melting can’t occur. You can heat any of the blades below with a lighter or similar tool.
Additionally, you’ll want to wear protective gear. Even if you do everything correctly, some cheap plastic sheets and boxes can break, and tiny, sharp plastic shards can fly into the surrounding area. Wear eye protection, specifically, to ensure that you aren’t blinded by this activity.
Lastly, using a pen or marker to draw lines for your cut is best. It’s especially helpful when using a power tool like a table saw, where cuts happen so quickly that you won’t be able to correct your cut if you make a mistake.
Now, let’s look at the tools you should use to cut plastic.
The 5 Best Tools to Cut Plastic Properly
1. A Utility Knife – Best for Thin, Softer Plastic
For thin sheet plastic, the best tool is a utility knife and a straight edge. You’ll score the plastic, then break it on a bench with a sharp edge. If this reminds you of cutting glass, you are correct. The technique is almost identical to cutting glass with a critical exception; you cut approximately ⅔ to ¾ of the way through the plastic versus scoring the glass.
You need a utility knife with a sharp blade and a metal straight edge with a precise edge. Avoid wood and plastic straight edges because you can damage them with your utility knife. Here’s a tip to see if your straight edge is straight or has a bow. Set the straight edge on top of your kitchen counter and look to see if any light comes underneath. No light = straight edge! We recommend metal rulers for this task.
Your technique is like that for cutting glass; mark your line, line up your straight edge, hold it firmly on the plastic, and make several slow passes with the knife blade tight to the straight edge. When you are nearly through your plastic, line the scoring up with the edge and briskly snap downward.
Hint: Keep your straight edge on top of the plastic when snapping. This protects the edge of the plastic from shattering or breaking at a point other than your line. This is especially important when working with brittle plastic like polycarbonate. For a sharp blade and durable frame, try the Milwaukee 48-22-1903 Fastback 3 Utility Knife.
- Press and Flip Opening, 4 Blade Storage
- All Metal Body, Quick Blade Change
- Gut Hook, Wire Stripper, 6.75" Length
- It’s a Milwaukee tool! Quality!
- Uses standard replacement blades and stores four in the handle
- Belt clip
- Folding
- Multi-purpose
- Expensive
2. Bench Top Band Saw – Best for Medium Thick Stock
Thick plastic is any plastic that’s thicker than ¼-inch. We recommend using power tools for these materials or containers.
Power Tools
With power tools, the trick is not to make such a powerful and aggressive cut that you end up splitting the plastic or melting it with the blade. To this end, be sure to heat the blade beforehand if possible (though this may be difficult depending on the power tool in question). Furthermore, remember to use thick gloves and protective gear.
The WEN 3939 2.8-Amp 9” Benchtop Band Saw is a perfect example of one of the best power tools for cutting plastic. It features a powerful motor with two speed settings that can rotate up to almost 2,500 ft./m and uses long 62-inch blades to make 8.85-inch deep cuts.
- 2.8 amp motor rotates the blade up to 2460 feet per minute
- Create cuts up to 3-5/8 inches deep and 9 inches wide
- Uses 62-inch blades anywhere from 1/8 to 3/8 inches in size
- Excellent value
- Plenty of power
- Takes readily available replacement saws
- Throat limits stock size
3. Compact Circular Saw – Best for Thick Plastic
Why shouldn’t you use a regular circular saw? It can work, except the tool’s size relative to the stock size can be an issue. Full-size circular saws are great on 2x4s and large sheets. They are not as easy to use on smaller plastic pieces, so we recommend the compact saw.
We think you’ll like the smaller saws because they are easier to control when working with small stock, provide better cut-line visibility, and don’t provide so much power that your stock vibrates and moves. Also, standard circular saws are too hefty to cut plastic lattice.
Plastic lattice is exceptionally flimsy, as you already know (or will find out). The weight of a giant saw will make the lattice sage and bow. Plus, it can increase the stock’s vibration when cutting. The compact saw has none of these issues. It is more manageable and bridges the open spaces quickly and easily. Mark your cut line clearly, clamp the lattice securely, and make the perfect cut.
The Rockwell RK3440K Versacut Compact Circular Saw is a powerful tool that is multifunctional, compact, and suitable for cutting other types of material like wood, tile, and even sheet metal.
- Powerful, 4.0 amp, multi-functional, ultra-compact circular saw
- Cuts wide variety of materials such as tile, wood, sheet metal, plastics, flooring, and more
- Ergonomic design with slim grip handle improves comfort and enhances grip and control – guide with just one hand
- Great quality
- Laser simplifies following the cut line
- Comes with a bag, blades, and other accessories
- Max cut depth is a little over 2”
Stock note: Cutting anything flat is fair game. Cutting round stock is not recommended.
4. Corded Jigsaw – Best for Curved & Complex Cuts
The versatile jigsaw takes second place in our reviews for cutting thick plastic. When used with an edge guide, it performs well in making straight cuts. It is also a top choice when making complex and curved cuts. So, why didn’t we put it first? The vibration is the short answer.
Jigsaws use a cutting action like the larger reciprocating saws. When the tool’s vibrations are transferred into the stock, control and precision become more difficult. This can be overcome in most projects by clamping the stock. However, cutting lattice with this tool is not the most pleasant of experiences.
You may need a jigsaw in your workshop at some point, and we recommend the Bosch JS470E Jigsaw.
- ERGONOMIC TOP-HANDLE: soft-grip areas supply a solid, comfortable grip
- CONVENIENT: featuring a tool-less blade change system and fast insertion with a blade ejection lever that eliminates need to touch hot...
- 4-IN-1: 4 orbital action tool settings provide different blade strokes for smooth to aggressive cuts for taking on the toughest cutting...
- Variable speed control
- Tool-less blade change
- Vibration reduction
- Bare tool – no accessories or case
Stock note: Good for straight and intricate cuts in rigid stock. It’s not the best tool to cut plastic lattice. Properly clamped round stock can be cut if the diameter doesn’t exceed the blade length. The accuracy of these cuts may not be the best.
5. Table Saw – Best for Large Projects
If you need long, straight cuts time and again, a table saw is the way to go. Portable saws are effective on thinner sheets, but we think you’ll like the power and precision of a genuine stationary table saw for ripping thick plastic.
The fence and miter gauge makes control and precision a snap, and the power of even a modestly priced saw is more than enough for plastic. The limitations of the table saw show up when you need complex and curved cuts.
The Grizzly G1023RLWX 10” Cabinet Table Saw provides an excellent, flat space to cut through any type of plastic, plus phenomenal guards to help you move a plastic sheet exactly where it needs to go. Remember that it’s for workshops due to its price and weight.
- All sealed ball bearing construction Serpentine drive belt Powder coated paint Quick change between riving knife & splitter guard Base...
- Outstanding quality
- Cast iron top
- Precision fence and miter gauge
- Straight cuts only
See Also: 9 BEST WAYS TO CUT STYROFOAM
Conclusion
The ideal tool to cut plastic depends on its thickness and your available tools. It’s best to use a utility knife for thin sheets, but for thick plastic, you’ll need power tools. Consider the previous options, and don’t be afraid to try multiple tools. Cutting plastic will become easier as you practice and gain experience.
Our related guides:
- Which tool performs best when it comes to cutting foam board?
- Which tool is best suited for cutting circles in wood?
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