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best way to cut 1/8" lexan sheet.
sealslayer:
I used a blade that has a hook shape to it, it scores so deep on 2mm plexi that you can snap after just one cut.
As long as you have a straight edge to score along it will work great.
AtomSmasher:
router and flush trim bit is the easiest way, you don't need to sandwich it between wood, but it couldn't hurt.
jcrouse:
Use a router bit in this:
NiteWalker:
Use a flush trim bit and a straight piece of wood or MDF. No need to make a wood sandwich. Lexan WILL NOT under ANY circumstances crack. The table saw also works fine. I rough cut on the table saw and then use a flush trim bit with my control panel templates to make an exact copy.
The score and snap methods don't work as well with Lexan. It usually leaves a rough edge that needs to be sanded. The router method is cut and you're done.