How to Cut and Drill Lexan: A Beginner-Friendly Guide (2024)

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Are you looking for an easy-to-follow guide on how to cut and drill Lexan? If so, you’ve come to the right place. In this article, we’ll provide all the information you need to know about cutting and drilling Lexan, a lightweight, high-impact plastic. From the right tools and techniques to safety considerations and tips for success, we’ll take you through the entire process, step-by-step. So, let’s get started!

What is Lexan?

How to Cut and Drill Lexan: A Beginner-Friendly Guide (1)

Lexan is a trademarked polycarbonate thermoplastic developed by GE Plastics. It is a lightweight, yet strong, material that is highly transparent, heat resistant and shatterproof. Lexan has been used for a variety of applications, including medical equipment, aerospace components, automotive components, aircraft windows and consumer products. It is also an ideal material for outdoor signage and displays, as well as for glazing in residential and commercial settings.

Interesting Facts About Lexan

  • Durability: Lexan is incredibly durable and can withstand extreme temperatures, impacts, and chemical attacks. This makes it an ideal material for use in aerospace, automotive, and consumer applications.
  • Transparency: Lexan is highly transparent and is ideal for glazing in residential and commercial settings. It is also used to create transparent signage and displays.
  • Lightweight: Lexan is extremely lightweight, making it easy to handle and transport. This makes it perfect for a variety of applications, including medical equipment and aircraft windows.
  • Shatterproof: Lexan is shatterproof, making it an ideal material for applications in which safety is a concern. This includes medical equipment, aerospace components, and consumer products.

Lexan is an ideal material for a variety of applications, from glazing in residential and commercial settings to aerospace components. If you are looking for a material that is lightweight, durable, shatterproof, and transparent, Lexan is a great choice. In this guide, we will provide you with step-by-step instructions on how to drill Lexan.

Benefits of Using Lexan

How to Cut and Drill Lexan: A Beginner-Friendly Guide (2)

  • Durability: Lexan is a highly durable, shatter-resistant plastic that can withstand extreme temperatures and heavy impacts.
  • Lightweight: Lexan is significantly lighter than glass, making it easier to work with and transport.
  • Flexibility: Lexan can be bent and shaped into the desired form.
  • Waterproof: Lexan is waterproof, making it suitable for outdoor use.
  • UV-Resistant: Lexan is resistant to UV rays, which makes it suitable for outdoor use.
  • Cost-Effective: Lexan is an economical material that is relatively cheap compared to other materials.

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What You Will Need

How to Cut and Drill Lexan: A Beginner-Friendly Guide (3)

Circular sawLexan sheets
DrillDrill bits
Safety gogglesTape measure
Face maskPencil
Work glovesVise

How to Cut Lexan

How to Cut and Drill Lexan: A Beginner-Friendly Guide (4)

Using a Hand Saw

A hand saw is an ideal tool for cutting Lexan due to its portability and precision. Start by marking your cut lines using a ruler and a pencil. Clamp the Lexan securely to a workbench and use a hacksaw to carefully cut along the marked line. Use a fine-toothed blade to get a smoother cut.

Using a Table Saw

Table saws are an effective way to make straight and fast cuts on Lexan. Secure the Lexan in place with clamps, then set the saw blade to the desired depth and start the cut. Be sure to wear safety glasses when using a table saw.

Using a Router

A router is a great tool for cutting intricate shapes in Lexan. Start by marking the cut line and clamping the Lexan securely to the workbench. Use a straight bit in the router to follow the marked line, and take your time for a precise finish.

Using a Jigsaw

A jigsaw is a great tool for making curved cuts in Lexan. Secure the Lexan in place with clamps and make sure it is firmly held in place. Use a fine-toothed blade and slow speed setting to get a smooth cut. Start cutting at the corner and follow the marked line.

How to Drill Lexan

How to Cut and Drill Lexan: A Beginner-Friendly Guide (5)

Drilling from One Side

Drilling Lexan from one side requires a sharp drill bit and a slow drilling speed. Start by drilling a small pilot hole first and gradually increase the size of the hole until you reach the desired size. Make sure to keep the drill bit straight to avoid cracking the material.

Drilling from Both Sides

Drilling Lexan from both sides is the best way to ensure a clean, accurate hole. Start by drilling a small pilot hole on one side and then flip the material over and drill the same size hole on the other side. This will help ensure both sides of the hole line up properly and reduce the chances of cracking.

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Tips for Cutting and Drilling Lexan

How to Cut and Drill Lexan: A Beginner-Friendly Guide (6)

Use the Right Tools: Lexan can be cut using a variety of tools, but the most effective way to cut it is with a jigsaw or a circular saw. It can also be cut with a knife, but this is not recommended as it could cause cracking or chipping of the material. When drilling, a high-speed steel drill bit should be used.

Mark Your Cut: Before making your cut, use a marker to draw a straight line on the area you want to cut. This will help ensure that the cut is straight and even.

Clamp the Lexan: When cutting or drilling, make sure to firmly clamp the Lexan to a workbench or other stable surface. This will help to keep the material from slipping or moving during the process.

Use Lubricant: When drilling, use a lubricant such as oil or wax to reduce friction and help the drill bit move more smoothly. This will reduce heat build-up and help to prevent cracking or chipping of the material.

Keep the Area Clear: Make sure to clear the area around the cut or drill site of any debris. This will help to reduce the risk of the debris becoming lodged in the blade or drill bit, which could cause damage to the material.

Go Slow and Steady: When cutting or drilling, take your time and go slowly and steadily. This will help to reduce the risk of cracking or chipping the material.

Safety Precautions for Cutting and Drilling Lexan

Wear Safety Gear: When cutting and drilling Lexan, it is essential to wear safety gear that includes safety glasses, gloves, and a dust mask. This will protect your eyes, hands, and lungs from any particles that fly during the cutting and drilling process.

Secure the Work Area: Make sure the work area is secure and free of debris so that the Lexan pieces can be cut and drilled without the risk of any dangerous objects or materials getting in the way.

Secure the Lexan: Secure the Lexan in a vise or clamps to ensure that it is stable and will not move while it is being cut or drilled.

Keep the Power Tools Under Control: Keep the power tools under control and make sure they are set to the correct speed and pressure to ensure that the Lexan has a clean and accurate cut or drill.

Clean Up the Work Area: After cutting and drilling, make sure to clean up the work area and dispose of any debris properly.

Store Lexan Properly: Store Lexan properly in a dry, dust-free environment to ensure that the material is not damaged by exposure to moisture and dust.

Frequently Asked Questions

What is Lexan and what is it used for?

Lexan is a thermoplastic polycarbonate material that is durable, impact-resistant, and lightweight. It is used in a variety of applications, including aircraft and automotive components, protective guards and shields, roofing and glazing, and in industrial and commercial applications. Lexan’s superior strength, transparency, and weatherability make it an ideal material for a wide range of applications.

What Type of Saw Should I Use to Cut Lexan?

The best saw to use when cutting Lexan is a circular saw with a fine-tooth blade. It’s important to use a blade with a high number of teeth per inch to ensure a smooth and clean cut. Make sure to use a saw with a low RPM (revolutions per minute) to avoid melting the plastic. It’s also important to use a steady, even motion when cutting.

What Tools Do I Need to Drill Into Lexan?

  • Drill: A drill with a high-speed steel bit is best for drilling into Lexan.
  • Drill Bits: High-speed steel drill bits are the best for drilling into Lexan. Other materials such as cobalt or titanium may also be used.
  • Screwdrivers: A variety of screwdrivers are needed for any kind of drilling into Lexan. Phillips head, flathead, and hex head screwdrivers are all necessary.
  • Clamps: Clamps are needed to hold the Lexan in place while drilling. This will ensure that the drill bit stays in the right position during the drilling process.
  • Safety Glasses: Safety glasses should be worn at all times while drilling into Lexan. This will protect the eyes from any debris that may be created during the drilling process.

What Types of Drill Bits are Best for Drilling Lexan?

Drilling Lexan requires special drill bits that are designed to cut through hard, brittle materials like polycarbonate. The best types of drill bits for Lexan include:

  • Carbide-Tipped Drill Bits – These bits are made of carbide and are ideal for Lexan as they can easily cut through it without cracking the material.
  • Titanium Drill Bits – These drill bits are made of titanium and offer superior cutting performance when drilling Lexan.
  • High-Speed Steel Drill Bits – These drill bits are made of high-speed steel and provide an excellent cutting performance when drilling Lexan.

It is important to note that these types of drill bits should only be used in a drill press, as they are not suitable for hand drills. Moreover, the drill should be set to the correct speed to ensure a clean cut and prevent cracking the material.

Are there any safety precautions to take when working with Lexan?

Yes. Taking safety precautions when working with Lexan is important to ensure you do not damage the material or injure yourself. Here are some safety tips to keep in mind:

  • Wear protective gear, such as safety glasses, gloves, and a dust mask.
  • Work in a well-ventilated area.
  • Ensure the area is clean and free of any debris or objects that could become a hazard.
  • Mark the area you are going to cut or drill to prevent mistakes.
  • Secure the Lexan to a stable surface before cutting or drilling.
  • Use sharp blades and drills to ensure a clean cut or hole.
  • Check the blades and drills regularly and replace them when they become dull.
  • Use clamps to secure the Lexan while cutting or drilling.
  • Start slowly and increase the speed gradually.
  • Do not allow the drill or saw to overheat.


Cutting and drilling Lexan requires patience, precision and the right tools. Following the steps outlined in this guide, you should be able to successfully cut and drill Lexan without compromising its structural integrity. Remember to use a cutting fluid to reduce friction and heat buildup and to be sure to wear the appropriate safety gear. With the right tools and techniques, you can get the job done safely and effectively.


How to Cut and Drill Lexan: A Beginner-Friendly Guide (2024)


How to drill Lexan without cracking? ›

When using hand drills, a slow speed setting works best with plexiglass and lexan. For drill presses, a slow speed is also recommended, but consult the manufacturer for the best settings for drilling plastics such as plexiglass acrylic and polycarboante lexan.

How to drill through plexiglass without breaking it? ›

Special spiral drill bits are best suited for drilling PLEXIGLAS® sheets. These have a special cutting geometry: Their cutting edges are ground in such a way that the material is scraped rather than cut. This prevents cracking and breakouts.

Can I use a Dremel to cut Lexan? ›

You can use a dremel, but keep the speed setting around 3-4, so you don't burn the lexan. It is a little tougher than acrylic.

Can you form Lexan with a heat gun? ›

We use a heat gun to heat it up and then bend it either on a table or by hand with gloves.

What are the disadvantages of Lexan? ›

Cons of Lexan:
  • Easier to scratch.
  • More expensive in comparison to acrylic.
  • Poorer clarity, cannot be polished to restore clarity.
  • Can be yellowed over time by UV rays.
  • Low level of resistance to abrasive cleaners and surfaces.
  • Can be dented easily.

How thick is Lexan bullet proof? ›

If the Lexan is over 1'' thick, it is considered bullet resistant. Is all Plexiglass bullet resistant? No, but it can be manufactured to be bullet resistant.

What is better than Lexan? ›

Sheet grade polycarbonate (aka Lexan or Makrolon) and acrylic sheet (aka Lucite) are two of the most frequently used see-through plastics. Each of the two have benefits and drawbacks. Acrylic is shinier and polycarb is stronger. Acrylic is less expensive but easier to crack.

What saw is best for cutting Lexan? ›

Best to use a band saw or a jigsaw and go slowly. we found that a table saw ususally chips lexan, but using a band saw slowly, but just fast enough not to melt the lexan is the way to get the cleanest cuts.

How to drill lexan? ›

for drilling, a HSS bit is good, but you want to use a slow speed to avoid melting. you are looking for a nice spiral chip as if you were drilling mild steel. also, use a center punch as its easy to slip off your point.

What speed do you drill plexiglass? ›

A cutting speed of approximately 400 RPM is recommended, feeding slowly when starting and exiting the hole.

What power tool is used to cut plexiglass? ›

In principle, both circular hand saws and jigsaws are suitable. For PLEXIGLAS® sheets of thickness up to 4 mm, you could also use what is known as a scriber.

How do you keep plastic from cracking when drilling? ›

Using a clamp to secure the plastic in place before you start drilling will ensure that the material stays still. If you do not do this, there is a greater chance of damaging the material.

What causes Lexan to crack? ›

RE: Lexan Cracking

All aromatic hydrocarbons and all chlorinated hydrocarbons cause the stress cracking even when present in very small quantities. Even if previously exposed, residual solvent that has been absorbed can be a problem.

Do you need a special drill bit for polycarbonate? ›

You can use an ordinary iron drill or HSS drill bit to drill holes in polycarbonate. Position the drill perpendicular to the polycarbonate and run the drill at medium speed immediately. Don't use too much pressure but let the drill do the work. It's important to use a drill that is not brand new but is still sharp.


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