Cutting plastic... tips?

[juggalofisher88]

Hey currently working on box mod...
I need to cut out 2 squares one for display, other for usb charger/powerbank
One HUGE problem I have no cutting tool. I had a dremel lined up but it was given away....
All I have is a drill and sharp knives lol
Any ideas? tips?

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[DeviantDigi]

I'd still try to get a Dremel tool. This one is $38: 40pc Flex Shaft Rotary Tool Kit Polishing Grinding Accessories Work with Dremel | eBay. There also one for like $12 on ebay, but it looks like poop. I bet it wouldn't have any problems with plastic though. Maybe you could get a deal on an auction?

But depending on the hardness of the plastic, a good ole' fashioned sharp razor blade should do the job. You just do multiple light passes. Same premise as plexi glass. An exacto knife would help clean up the edges and corners.

You could also try drilling out a bunch of wholes in the center of you square. And cutting out the pieces with some sturdy scissors or shears.

 

[juggalofisher88]

Yeah iv put it on the back burner till I get hold of a dremel if I get restless I'll try a exacto knife.


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[LDS714]

If you're going to use the Xacto, you may want to try heating it before each (small) cut.

 

[juggalofisher88]

Thanks

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[TheRac25]

drill out as much as you can, rough it out as much as you can with side cutters, finish up with ???/files/sanding

 

[Doghead]

People used to build houses with hand tools. Use a straight edge, blade, and go slow. Only go for a little depth at a time. The heat thing will work wonders too, just avoid too much force. That's when things slip and people need stiches!


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[Froth]

A hot/torched x-acto knife will work quite well.

 

[Vapant]

I'd drill a small hole in each corner and a large one in the centre, use a hacksaw blade by itself and cut from the large centre hole to each corner hole, this will leave you with 4 triangles to score with a knife on both sides and gently bend back and forth until they snap off.
Keep the corner holes (and score lines) slightly in, away from the finished cut out so you can tidy it up with a knife, small files and/ or sandpaper.

Careful when using snap off blades, they can be unpredictable, especially if you put any sideways pressure on them so don't expose too much blade and don't use them blunt as you would need more pressure=more chance of snapping.

 

[asdaq]

The dremel would be too hot and actually melt more than cut. If you drill near the corners but smaller than you need and shape and expand with diamond needle files, you can get a near perfect window, beveled and all. A decent set of 5 files should cost about the same number in dollars.

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[DeviantDigi]

The dremel would be too hot and actually melt more than cut. If you drill near the corners but smaller than you need and shape and expand with diamond needle files, you can get a near perfect window, beveled and all. A decent set of 5 files should cost about the same number in dollars.

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Maybe you need sharper drills bits .

You can cut plastic even with a rotary tool. The plastic melts, but you get a very clean line and corner. The excess build up on the top snaps right off.

 

[kaddigart]

The closest I've ever gotten to a perfect square in plastic is with the drill/file method. Drawing the shape on the plastic with a lead pencil is extremely helpful no matter your method. A set of needle files can be had for under $10, and they work well with most any material.

I found the Three-Square best for corners and a pillar type (they only cut from the widest flat side) for the lines between the most effective. Given the size of the holes you need the files would work with little effort.

 

[csardaz]

Coping Saw would be perfect

A wood chisel - as if cutting a hinge mortise.

A soldering Iron (tip may not be good for soldering afterwards) They make "Hot Knives" just for cutting plastic - just like a soldering iron but with a blade like an exacto on the tip. Ventilate good melting/burning plastics.

You may not have extra plastic to experiment with but if its brittle then sometimes a short bath in hot water makes it soft enough to avoid chipping or cracking.

If the edges end up rough - sometimes a torch or lighter to just slightly melt/soften will smooth or even polish the edges.

A lot depends on what type of plastic.