Which is the best way to cut Lexan?

I am planning to make a big hole in my side panel for a window and then make a round hole in the windows for a fan. So now I have got the side panel all taped up and is ready to cut. But here I have some doubt that how to cut the Lexan. I got this new Lexan but I got stuck here and don’t know how to proceed further. I don’t actually know how to go about it. So if anyone knows the solution to this then does get back to me immediately.

I just had a look at your question and feel that you should begin cutting the area that is not that much important. So start with that area that is not of utmost importance like the scrap piece if possible. So consider that if you have a 120mm hole to cut-out then cut the 50-60mm hole out of that 120mm hole. Try this solution and I am sure it will help you to cut the Lexan and am sure that it will be very helpful to you to cut the Lexan.

According to me what you need to do is that you should support the target piece entirely under its surface. Also I would like to tell you that you should cut both the target piece and also the supporting sacrificial piece. This is an important point that you need to remember. Also if you wish that you need to complete it like a professional then you should find a CNC Millers.I feel that if you find them then your job will be done easily.

Thanks a lot for your solutions. I just went through them and feel that they will be really handy to me. Also I have would like to tell you that I got a new multipurpose cutting kit in order to cut the Lexan. But I am yet to use it. I don’t know of how much help it will be but I feel that it will be useful to cut the Lexan. But right now I am having both the straight and curve cuts that are needed to cut the Lexan. So I am sure that they will be of real use to me.

Even I was facing with a similar kind of doubt but found out a way to solve this problem. What I did was I used a regular power jigsaw. That helped me a lot. In that the edges were not presentable but they were all hidden and that worked in my favor. But the drawback over here was that the heat from the blade melted the plastic somewhat but that didn’t cause a major damage fine. But even I feel that you should try this solution and I am sure it will be of great help to you. Also I think that you can find a solution to polish the edges if you need want.

I think that if you can use a saw or any other tool then that speed is important. Also you need to notice that you don’t melt the cut. And also the speed at which you push or pull the tool through the material is important at the same time. I would also say that you can even go with the fine tooth haxsaw blade as well. So there are quite a few options that you can go with and I am sure that this will be of greater help to you.