The Art of Machining Custom Acrylic: A Comprehensive Guide (Part 1)

Acrylic, also known as Plexiglas or Perspex, is a versatile material loved by craftsmen and engineers alike for its transparency, durability, and ease of machining. Whether you’re a hobbyist or a professional, this comprehensive guide will help you unlock the full potential of machining custom acrylic.

Getting Started

1. Understanding Acrylic

Before you dive into machining, it’s crucial to understand the material you’re working with. Acrylic is a thermoplastic known for its optical clarity and remarkable strength. It’s available in various grades, custom acrylics extruded and cast acrylic, each with unique properties.

2. Essential Tools

To begin machining acrylic, gather the necessary tools:

  • Circular saw or jigsaw
  • Router
  • Drill press
  • Clamps
  • Acrylic-specific cutting tools

Cutting Acrylic

3. Cutting Techniques

Precision is key when cutting acrylic. Use a circular saw or jigsaw with a fine-toothed blade to prevent chipping. Support the material adequately to minimize vibrations, and ensure your workspace is clean to avoid dust and debris on the acrylic’s surface.

4. Proper Clamping

Clamping acrylic sheets securely is essential to prevent shifting during cutting. Use clamps with soft jaws or insert soft materials like wood or foam between the clamp and acrylic to avoid scratching.

Drilling Holes

5. Drilling Tips

Drilling acrylic requires care. Use a drill press with a slow speed setting and a sharp, high-speed steel bit. Begin with a small pilot hole to prevent cracking. Secure the acrylic sheet firmly to the work surface.

6. Reducing Heat Build-Up

To avoid heat damage, use a lubricant, such as water or a specialized acrylic coolant. This helps to dissipate heat during drilling and extends the life of your drill bits.


Mastering the art of machining custom acrylic begins with understanding the material, gathering the right tools, and practicing proper techniques for cutting and drilling. In part two of this guide, we’ll explore shaping and finishing acrylic projects. Stay tuned for more insights into creating stunning acrylic creations.

Leave a Comment