Collection: How to Cut Multi-Wall Polycarbonate

This guide will walk you through the process of cutting your multi-wall polycarbonate panels yourself. With the right tools and tips, you’ll be able to make clean, accurate cuts and get your panels ready for installation. Let’s get started!

Not sure about cutting the panels yourself? Reach out to our team for custom options—we’ll give you a fast quote and handle it for you!

Cutting Thinner Polycarbonate (4 mm, 6 mm, 8 mm & 10 mm)

• Box Knife (NOT recommended): You can use a box knife for small cuts, but it’s tricky and not ideal for larger jobs. Start by lightly scoring the panel, then go over it with more pressure. When you’re almost through, you can flex the panel to snap it apart. Be careful to keep your hand away from the knife! This method tends to drag and skip the knife, making it dangerous to use.
• Circular Saw / Saber Saw: These tools are great for bigger projects. Use a fine-tooth blade (a plywood/finish blade for circular saws and a metal-cutting blade for saber saws). Clamp a straight edge to guide your cut. Just like cutting plywood, going too slow can cause melting, and going too fast can splinter or shard the material. A steady pace works best, and it’s a good idea to test your cut on a piece that won’t be noticeable in your project.
• Table Saw: For larger jobs, a table saw with a fine-tooth blade is your best bet. Slowly push the polycarbonate sheet through the saw, just like you would when cutting plywood paneling. Again, a calm and steady pace ensures the best results.

Cutting Thicker Polycarbonate (16 mm and 25 mm)

• Table Saw / Circular Saw: These are the best tools for thicker panels. A saber saw can also help for cutting holes or rounding corners.

Pro Tips

Know Your Sides

Polycarbonate panels have a protective film on both sides. One side is clear, and the other has blue film or printing—that’s the UV-protected side, and it needs to face outward to be effective. Only remove the protective film from the inside of the panels before installation. Peel back the outside protective film about 4" from the edge, but leave it on until installation is complete. Since it can be hard to tell the inside from the outside once both films are removed, mark the outside edge of the panel with a permanent marker to avoid confusion.

Cutting and Cleaning

After cutting, small particles may sneak into the flutes (the channels in the panel). Use compressed air to blow them out or a vacuum to clean them up. Avoid using water—it can take a while to dry inside the flutes.

By keeping these tips in mind, you’ll have clean cuts and your panels ready for action!