Best tools for cutting polycarbonate sheets?

[MRK]

I'm going to "fabricate" a window made out of 1/8" polycarbonate sheet. I was going to use a jigsaw on a slow oscillation with a fine blade to rough it out and then a palm sander to finish it.
What say you??
Thanx in advance, Mike

[RichFox]

Pretty much what I did. Didn't really worry about blade speed on my jig saw.

[Eddieschopshop]

Yup Jigsaw will go through like butter,  not as brittle as plexi so won't crack or blow out from the cutting as easy

[Bob Drury]

  As for drilling holes (as if You asked) I know that TAP Plastics has specialty drill  bits for sale.  Any one out there had good or bad luck drilling holes?
                                                                      Thanx, Bob

[jdincau]

Leave enough excess with the saw so you can sand the edge smooth. The smoother the better, it will help prevent crazing later (yes crazing with Lexan). Drill the holes oversize to prevent stress cracks.

[noboD]

For straight cuts use a sheet metal sheer. It can also be bent in a brake.

[Speed Limit 1000]

Trepan drill bits drill clean small holes. Unibits are good for larger holes. Baby oil is a good lube. Run the drill in slower speeds to keep from melting the plastic, a little practice drilling on scrap will help.

[RichFox]

I use a center drill. Plexy or Lexan works great. As long as that is the size you want.

[hotrod]

Here is a video of a guy doing an 1/8 inch lexan windshield for a plane.
Guy does the major cuts with tin snips on lexan this thick, smooths edges of cut with a carpenters block plane and final cleanup of the edge with sand paper.
Makes some interesting observations about heat forming it with a heat gun as well.

Just a bit of not work safe "tradesman" language.

https://www.youtube.com/watch?v=z8TjOGy0b-U

Cold bending with a sheet metal break

https://www.youtube.com/watch?v=sNWqbAz6Lww

Hot bending with heat gun

https://www.youtube.com/watch?v=6ik-wqRNFSE


Interesting vacuum forming setup (example using styrene plastic)
https://www.youtube.com/watch?v=maH5Ech0wK8

[t-rod]

I happen to work in a plastic fab shop. I imagine no one needs to vacuum form polycarbonate for car windows, but polycarb doesn't form as easily as styrene. Jigsaws and sheet metal shears work great on polycarb.

Sent from my SM-G386T using Tapatalk

[MRK]

Great stuff. I'm inspired! Thanx to everyone who posted.

[wobblywalrus]

A steel burr in a Dremel tool is what I use for drilling and cutting thinner and smaller pieces like bike windshields. 

[floydjer]

Single flute bit in a router makes short work of it as well.

[Speed Limit 1000]

Single flute bit in a router makes short work of it as well.