High Density Polyethylene (HDPE) is a general purpose food grade plastic approved by the FDA and USDA. HDPE sheets are cut-resistant and milky white. As with most thermoplastics, the heat generated during the cutting process causes the plastic to melt and fuse together behind the cutting blade. Using the correct cutting tool and lubricating the cutting area will ensure success when cutting HDPE plastic.
The advantage of the HDPE sheet is that it can be cut with tools that many people already have. If you treat it like wood, you will be successful in cutting and drilling. The best results with a circular or panel saw are with carbide teeth. Standard miter and jigsaw blades can also cut curved or other geometric contours. Tool blades need to be sharp to obtain the best results.
HDPE Sheets
For cutting thicker acrylic and polycarbonate plastic sheets (greater than 1/3" thick) in a straight line, a table saw or circular saw is required. Use a blade specifically designed for cutting plastics, usually packaged as a "non-melting" blade. Ideally, the teeth of the blade should be evenly distributed, of uniform height and shape and close to each other.
Widely spaced teeth can cause the plastic to shatter or break. Please note that if you choose to use a regular blade rather than a 'non-melting blade, the excessive heat generated may melt the plastic. As a precautionary measure, pause between cuts to allow the blade to cool.
Mark the line to be cut with a permanent or greasy mark.
Use clamps to secure the plastic to the work surface.
Cutting plastic with a circular saw (or table saw) is the same as cutting wood.
HDPE Sheets
To cut thin sheets of acrylic or polycarbonate (up to 1" thick) directly, take a simple hobby knife and follow these steps
Use a paper clip to secure the sheet to a larger work surface.
Mark the desired cut line with a straight edge and then use the hobby knife to cut the plastic sheet several times until a deep groove is formed. You may wish to cut the line more than halfway down the plastic line.
Turn the sheet over and repeat the scoring process along the same cut line on the other side.
Reposition the plastic on the work surface to align the groove with the edge of the work surface. Use the clips to hold the plastic in place.
Finally, the hanging part of the surface is broken.
HDPE Sheets
For curved or round plastic cuts, a jigsaw is the best option, whether you are using thin or thick sheets. Ideally, you will use a sharp blade designed for plastic. You can also use a blade marked for wood, but the friction of the blade can generate too much heat and cause the plastic to melt after cutting. To avoid this, you may need to try different jigsaw settings and speeds with a piece of scrap plastic. Use the jigsaw according to the manufacturer's instructions and you will have a perfectly cut piece of plastic for your next home repair or DIY project.
Always take proper precautions when cutting plastic with jigsaw. Use a vise to secure the plastic piece to the workstation to ensure it doesn't move during the cutting process and wear safety glasses to protect your eyes from acrylic or polycarbonate chips.
Unlike other materials, Abosn HDPE sheets do not rot, splinter, chip, swell and it is also termite resistant, it offers a much longer life compare to other materials. Even when installed outdoors, or anywhere in harsh weather and conditions, its performance remains unchanged. If you want to get more information about the best HDPE sheets, welcome to contact us today or request a quote.
