Flush Trim Router Bit & Plexiglas/Lexan

[gamepimp]

Hi guys. I'm getting ready to embark on redoing my CP and this time around I will have artwork covered by 1/16" plexi or Lexan (haven't decided which one for sure yet). Just wondering if I can use my router with the flush trim bit to bring the edge of the plastic to the edge of my CP (which will be MDF) as well as to clean out the holes for buttons/joysticks. My concern is that the bit might end up melting the plastic instead of trimming it. Has anyone tried this?

[shponglefan]

I've used it for trimming edges around the CP, but not for cutting holes in plexi (for that I use a hole saw).

I found it cut through it very easily and didn't have any issues w/ melting.  Just try it out with some scrap first to get an idea of how fast to go.

[gamepimp]

Awesome. I'll give it a shot. Thx!

[yaksplat]

a flush bit works like a champ on plexi and lexan.  Just use the proper speed for the diameter of thie bit, the small er diameter, the higher the speed.  It will not melt the plexi.  I've done 7 panels and not had any problems with melting.

[gamepimp]

That's really good to hear. I think it will make my life much easier. 

[selfie]

I use a flush trim bit on acrylic(plexi) daily with no dramas at all.

Polycarbonate(lexan) is a softer material and can cause issues if not trimmed with a sharp bit. A blunt bit will cause too much heat build up and the shavings can weld themselves together creating blobs of material that can stick to your workpiece. This is true for all extruded materials. Cast acrylics do not tend to do this.

[gamepimp]

I was leaning towards plexiglas. So I guess this just reaffirms that as the best choice. Thx for the input!