Cutting polycarbonate - how?

[barnaclephill]

' have been given some 10mm polycarbonate to make a companionway window in one of the boards. How do I cut this stuff - with a slow speed and fine-toothed jigsaw? Hacksaw?

How would I arris the edges of it also - hand sanding, flapper disk on the angle grinder?

 

[ccscott49]

Jigsaw with fine blade, sanding by hand with a block is best.

 

[oldsaltoz]

A standard Router will give a nice edge finish.

 

[Guest]

I find it best to rough cut with a jigsaw and then use a router with a follower type straight cutter.

By clamping a flat straight edged piece on top and using the follower bearing you do not end up with scrape marks on any unprotected parts that the protection plastic has ripped from.

Polycarbonate is more prone to surface scratches than acrylic.

Using a router it is much easier to get a good fit as you can remove very small amounts. If the router has good bearings then the edge is quite acceptable.

 

[cliff]

At 10mm thick a medium - coarse blade will suffice and will be less prone to clogging. If cutting on a band saw a 10TPI blade and slow speed to avoid heat build up. If a circular saw a fine tooth and 0° to ~ 5° negative rake and slow feed speed.

Routers already covered however use a SHARP cutter and be careful of heat buildup.
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[orizaba]

as above but it may help to put a trip of masking tape down your cut lines,it helps prevent chipping ,scratchs etc especially if you are using a saw

 

[savageseadog]

Leave or put on protective film

 

[Robin2]

Very easy to cut. A Bosch T101B blade or Hitachi equivalent (JW10) in a jigsaw gives a near perfect cut. Unlikely to need sanding.