[ARC5] Working With Lexan

[Michael Hanz]

Just to add another option, I have always used my band saw with an 18 
TPI x 1/2" skip tooth cutting blade and ~2000 FPM blade velocity.  The 
thickest block of Lexan I've ever had to cut was 3", but it cut that 
smoothly without a problem.  It helps to have compressed air on the 
blade to clear chips before the blade enters the workpiece, and will 
also help to keep the heat down.

- Mike  KC4TOS

On 11/9/2019 10:47 PM, Peter Gottlieb wrote:
> They now have reinforced cut off disks for Dremel which use a special 
> mandrel and snap in disks.  You cannot break those disks and can go to 
> much higher power, shower of sparks when cutting steel level of 
> power.  You can get them at Lowe's or Home Depot.
>
> On 11/9/2019 9:45 PM, Robert Eleazer wrote:
>> In reference to Mr Stinson's recommendations about using Lexan 
>> from early in the week, I have found that the very best way to cut it 
>> is with a Dremal cut off wheel.  Be sure to have a box of the cut off 
>> wheels handy, since any sideways pressure will result in the wheel 
>> breaking.  I have cut rather long stretches of Lexan for airplane 
>> windows and the Dremal approach works fine.  The edges may be a bit 
>> melted but an X-Acto knife cleans them right up.
>> Harbor Freight sells a cheap Dremal-type tool for around $7 but it is 
>> so low powered that you may fall asleep when cutting something as 
>> tough as 0.60 Lexan.  It is FB for model kits, since it takes 
>> much longer to do damage than the more powerful rotary tools.
>> Also, older Lexan sheets may present a problem with getting the white 
>> protective backing off.  The best way to do that is with denatured 
>> alcohol.
>> Wayne
>> WB5WSV