Quck answer
Cutting an acrylic lighting panel can be done with a few simple steps:
1. Measure and mark the desired size on the panel using a ruler and a marker.
2. Use a sharp utility knife or a circular saw with a fine-toothed blade to score the panel along the marked line. Apply even pressure and make several passes until the score line is deep enough.
3. Place the panel on a flat surface with the scored line hanging over the edge. Apply downward pressure to break the panel along the scored line.
4. Use sandpaper or a file to smooth the edges of the cut panel.
5. Clean the panel with a soft cloth to remove any dust or debris.
With these steps, you can easily cut an acrylic lighting panel to the desired size for your project.
If you have recessed fluorescent lighting in your kitchen or workshop, it is likely covered by an acrylic lighting panel that serves as a diffuser. Typically, these panels are less than 1/4-inch thick and have dimples on one side to scatter the light more effectively. Some designer kitchens have a dome pattern of fluorescent lighting covered by Lumadome ceiling panels or other brands.
Acrylic panels have a limited lifespan, and when they become cloudy, it is time to replace them. However, the standard sizes may not fit your fixtures, so you will need to cut them to the right size. There are several methods you can use to do this.
Best Approach to Cutting Light Diffuser Panels
Plaskolite, an Ohio-based brand that manufactures acrylic and polycarbonate lighting panels, provides the recommended cutting process in a YouTube video. This method, similar to cutting glass, requires a plastic cutting tool or a sharp utility knife, a straightedge, and a pair of C-clamps.
Start by placing the plastic panel, dimple side down, on a work table. Use a tape measure to measure the cut line and make marks on both ends of the panel with a felt-tip marker. Then, move the panel to the edge of the table, allowing the cutoff to hang over. Position a straightedge on the marks and use C-clamps to secure the straightedge to the table. Tighten the clamps enough to hold both the straightedge and the panel in place.
Using a plastic cutter or utility knife, score along the straightedge multiple times until the score line extends halfway through the panel. Carefully break the panel along the line, starting from one end and working towards the other.
Cutting Translucent Panels
The score-and-break method can be time-consuming for thick panels or when cutting multiple panels. It is also not suitable for curved cuts.
As an alternative, you can use a power saw to cut acrylic plastic sheets. A&C Plastics Inc. recommends using a scroll saw for straight and curved cuts as it generates less heat and reduces the risk of melting.
You can also use a table saw for cutting translucent panels, but you will need to make two modifications to your tool. First, attach a flat strip of plywood to the fence to fill the gap between the tool’s bottom and the table, preventing the panel from going under the fence. Second, replace the utility blade with a laminate-cutting blade that has at least 80 teeth. Apply masking tape along the cut line and pause the cut if you notice smoke, indicating melting plastic. Resume cutting once the plastic has cooled.
Other Methods for Cutting Acrylic Panels
Thin lighting panels can chip when cut with a table saw if not properly supported. To prevent this, you can use a rotary tool, which is safer than a saw blade. Mark the cut line, clamp the panel to a workbench with the cutoff hanging over the edge, set the tool’s speed between 10,000 and 15,000 rpm, and cut along the line.
If you only have a circular saw, you can still cut the panel by following these steps. First, replace the blade with one that has at least 80 teeth. Then, find a spare piece of plywood that you don’t mind damaging and place the panel on top of it. Adjust the cutting depth of the saw to be 1/8 inch deeper than the thickness of the panel. Next, apply masking tape along the line where you want to make the cut. Secure the panel to the plywood with clamps. Finally, start cutting slowly, allowing the saw to gradually penetrate the plywood as it cuts through the panel.
