How can the acrylic sheets be cut and refined?

Acrylic sheet

Acrylic or PMMA is a synthetic polymer and a transparent thermoplastic. It is lightweight and shatter-resistant therefore it is used as an alternative to glass. It has properties like impact resistance, 92% of light transmission, UV stability and scratch resistance.

It is easy to handle and process acrylic and it does not contain any harmful compounds. Before installing acrylic sheet you need to cut or saw and sand them. Thin acrylic can be easily cut using the scoring method otherwise saws can be used. Sanding is done to refine the cut edges and give a good finish. 

Cutting acrylic 

Scoring 

Put the sheet on a flat surface as this will make it easier to work with. The surface should accommodate the sheet and it should be raised as you will need the edge to break the sheet. Make a line from where you want to cut the sheet by using a ruler and a permanent marker.

Using the ruler as the guide, use the plastic scoring blade to score the cutting line. Try to make a continuous line with even pressure. Run the blade over the line and deepen the cut. Repeat the process until you have a substantial grove. Turn the sheet and follow the line on the backside and score it.

The line you have scored should be placed on the edge of the surface. Use clamps to hold the sheet on the surface. Press down the outer edge in quick motions to break the sheet at the score.

Sawing

Use a blade that is made especially for acrylic as it will help to make cleaner cuts. First, mark what you want to cut using a permanent marker. You can use a circular saw, table saw or saber saw to make straight cuts. To cut out curves use a jigsaw.

Start cutting from one side of the sheet where you have made the mark. Do not move quickly as it will produce rougher edges and do not move too slowly as it will melt the PMMA. You should constantly keep an eye on the blade and your line to cut.

Sanding acrylic

When you cut or saw acrylic it leaves rough edges and you need to even them. You can use a metal file to file down the sharp burrs.   

You can use sandpaper or a sanding block too. Apply water to the sandpaper and sand down the edges. Use fine sandpaper if you need a finer edge. Use waterproof sandpaper that is made for plastic.

You can buff the edges down to get a smooth finish. Attach a buffing edge to the electric drill. Rub the buffer with a polishing compound and buff down the edges until they are smooth and shiny.