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Cutting Polycarbonate/Perspex


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Drill press for cutting circles with a hole saw is how I used to make plastic protectors before someone much smarter realised there was money to be made. Drilling with a press isn't the way I would recommend cutting acrylic but at high speed with a milling bit might do the trick or just set up a router upside down under an old table and cut that way. . Has anyone tried a nibbler on this stuff?
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Jigsaw and router I have been using. Jigsaw to cut the sheet to the required width and router to cut perfectly square slots in it.

 

Router tip I am using is a flat tip and it is giving me the desired 90 degree edge and I found best to hit it hard with the router as going slow was heating up the poly-carbonate to much.

 

None the less, any "plastic melt" is quite easy to snap off clean. The material I'm using is 4.5mm thick.

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