I'm interested in what to use when drilling and cutting the material. I worked with regular plexiglass before and they chipped very easily when drilling holes. Anyone have first hand experience working with Lexan.

 

I worked with it alot. My radio controlled truck bodies are made out of it. so I can only tell you from that but I will try and help any way.

It cuts very easily.. DREMEL is the best tool for it. using a drill for holes and then a sanding bit for cutting. YES i use a sanding bit in my dremel tool to sand down parts instead of cutting. But the reason for that is it is small. you can cut it with a utlity knife and there is very little chipping..NONE.

any other questions?? again lexan is lexan.. but my use is about 18 inches long by 6 inches wide.

 

I've used modelling scissors to cut it. When drilling, there is no chipping.

If you need to drill holes, do what bags does, use a sanding bit.

 

I got a sheet from Home Depot and when I drilled holes there was no cracking....heres a pic of my creation--->

 

Like Plexiglass, Lexan is a derivative of a lucite polycarbonate. If your dealing with thicker sheets (.125"+), drilling should be fine. Just make sure you start with a small bit, and then work your way up to a larger bit until you reach the size hole you want. Use carbide tipped, or even better, titanium nitrided bits and you should be fine. If your dealing with thin sheets, like RC car bodies, a hole punch and hammer will do to start the hole, and use a tapered reamer to enlarge until you achieve the desired bore size.

 

for screw sized holes what i do is get a nail put it in a pair of visegrips and use a tourch to heat up the nail and then just push it through, cuts like butter nice and easy and no chipping since it melts a hole right through

Dave