What is the best way to cut lexan, i’ve been taking a hacksaw and cutting it, but I feel like there is a way significantly better way to do it

It depends on how thick is the lexan. So far, we used scissors and pen-knives.

For perfectly straight cuts I find a plastic scorer and a straight guide to be the best, yet when curves are involved we usually use a table saw and guide the sheet to what we need

Scroll saw works very perfectly. Cheapest option is tin snips which also works very well.

I personally use the “score and snap” method where you score the plastic with a knife and then break it in half. The High School teams at my school also use a waterjet cutter and you can get some great results with that.

if you have access to a waterjet, the results can be amazing and accurate. other than that, a bandsaw would also work perfectly when precision isnt a problem

Depends on what you have available. If all you have is a hacksaw, hacksaw it is. You got a dremel, then probably the dremel. If you have a bandsaw, then probably a bandsaw. If you can use a water jet cutter, probably the water jet.

There are also tools (like this one ) designed specifically for cutting sheet plastic, available inexpensively at your local hardware store.

I’m going to second tin snips. Team 10 has been using them for plastic sheeting for as long as it’s been allowed in VEX. One major thing they have going for them is that they are significantly less dangerous than a lot of other ways of cutting plastic (knives, power tools, etc.).

Thanks for all the reply’s, I’m probably going to get the tin snip and or the scorer, im in a team with my friend so I don’t have access to the larger tools like a band saw or water jet .