Cutting expanded PVC sheet, like Sintra® Material, is straightforward using common tools and techniques. The most effective methods include knife cutting, sawing, and routing operations.
Expanded PVC sheet is a versatile plastic often used for signage, displays, and fabrication. Knowing the right cutting method ensures clean edges and prevents damage to the material.
Recommended Cutting Methods
Based on common practices for materials like Sintra®, there are several reliable ways to cut expanded PVC sheet:
- Knife Cutting: Ideal for thinner sheets.
- Sawing: Suitable for various thicknesses, using appropriate blades.
- Routing: Provides precision and allows for complex shapes.
Using the correct tool and technique for the sheet's thickness is crucial for a professional finish.
Knife Cutting Expanded PVC
For thinner expanded PVC sheets, a knife or blade is an effective tool. The reference specifically states that materials up to 3mm thick can be cut with a knife or blade.
- Suitable Thickness: Up to 3mm.
- Tools: Utility knife, craft knife, or specialized plastic cutting blades.
- Technique:
- Use a straight edge as a guide.
- Score the material several times along the cut line with firm pressure.
- Once sufficiently scored (often through a significant portion of the thickness), you can snap the material along the line.
- For thicker sheets within the 3mm limit, multiple passes are essential.
This method is quick and requires minimal equipment, making it excellent for small cuts or thinner materials.
Sawing Expanded PVC
Sawing is a common method for thicker expanded PVC sheets and for making longer or straighter cuts.
- Suitable Thickness: Various thicknesses, especially thicker sheets where knife cutting is impractical.
- Tools:
- Circular saw
- Table saw
- Jigsaw
- Band saw
- Blades: Use fine-tooth blades designed for cutting plastic or non-ferrous metals. Standard wood blades can chip the material. A negative hook angle blade is often recommended to prevent chipping and grabbing.
- Technique:
- Ensure the sheet is well-supported to prevent vibration.
- Use a steady, controlled feed rate.
- Avoid excessive heat buildup, which can melt the plastic. Some recommend cooling the blade or the cut area, especially for thicker pieces or high-speed saws.
Sawing is versatile and allows for various types of cuts depending on the saw used.
Routing Expanded PVC
Routing offers high precision and the ability to create intricate shapes, curves, and cutouts.
- Suitable Thickness: Various thicknesses.
- Tools: CNC router or handheld router.
- Bits: Use straight or spiral router bits designed for plastic or acrylic. Single flute bits are often preferred for preventing chip welding.
- Technique:
- Secure the sheet firmly to the router bed or workbench.
- Set the correct spindle speed and feed rate to achieve a clean cut without melting.
- Ensure proper chip evacuation.
Routing is excellent for professional applications requiring detailed or consistent cuts.
Methods Generally Not Recommended
While some plastics can be cut with shearing tools, shearing with a guillotine shear is generally not recommended for expanded PVC material like Sintra®. This method can compress, deform, or crack the material rather than providing a clean cut.
Summary of Cutting Methods
| Method | Suitable Thickness | Primary Tools | Advantages | Considerations |
|---|---|---|---|---|
| Knife | Up to 3mm | Utility knife, Craft knife | Simple, low cost, portable | Limited to thin material, requires scoring/snapping |
| Sawing | Various | Circular saw, Table saw, Jigsaw | Versatile for straight cuts | Requires proper blade, support, and heat management |
| Routing | Various | CNC Router, Handheld Router | High precision, complex shapes possible | Requires specific bits, dust collection, and setup |
| Shearing | Generally Not Recommended | Guillotine Shear | --- | Can deform or crack the material |
Choosing the right method based on the thickness of the expanded PVC sheet and the desired cut quality is key to successful fabrication.
