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How to Cut Epoxy Resin Like a Pro

Why is Hard to Cut Epoxy Resin?

Resin Pen Blanks

Epoxy resin is a material that is difficult to cut after it has cured because it is hard and brittle. It is made up of two parts, the resin, and the hardener. When these two parts are mixed together, they form a tough, clear plastic. Epoxy resin is often used in crafts and hobbies because it can be molded into different shapes. It is also often used in the marine and manufacturing industries, and to make epoxy resin countertops, floors as well as hobbyists’ projects and also in the construction industry.

Cutting epoxy resin doesn’t require any special equipment, however, because of its nature as a hard and brittle plastic, a bit of forethought and planning is necessary.

Tools You Can Use to Cut Resin

  1. Table Saw
  2. Circular Saw
  3. Band Saw
  4. Router
  5. CNC Machine
  6. Reciprocating Saw
  7. Box Cutting Knife
  8. Drill
  9. Angle Grinder
  10. Orbital Sander
  11. Dremel/ Rotary tool
  12. Hach Saw

The Best Way to Cut Epoxy Resin

In order to cut epoxy resin like a pro it is necessary to always use sharp blades and cutting tools.

A dull blade will chip the resin on the outstroke of the cut generally on the rear surface of the workpiece and make the tool more dangerous to use.

The higher the number of cutting surfaces or teeth the better and smoother the cut because each tooth passes through the workpiece it scrapes a small amount of material into the gullet of the blade to be expelled from the workpiece.

There is no one best method to cut resin.

The best method is to use the tool that will perform the cut that you want to achieve. for instance, if you want a straight cut on a large piece then a circular saw with a straight edge or a track is the best method while if the piece is small then a table saw or a band saw may be the best option.

Using woodworking cutting tools is also the go-to option when you have mixed the resin with wood for your projects like a resin table or cutting board.

Methods of Cutting Epoxy Resin

Cutting Before the Resin Has Fully Cured

Always cut epoxy resin with a sharp blade or box cutter before it has fully cured is a quick and easy way to remove over-pour or drips from your project.

The epoxy resin is left to cure to a gell state before it has hardened to its final state. a box cutter is used to slice off the overhang or drips, as the epoxy is still soft it is easy to slice with a simple sharp knife.

However, there is only a short window that this method will be effective it will only work when the resin is in a semi-solid gel state too soft or too hard and the knife won’t cut the epoxy resin. this is best method to cut small projects like coasters where is it difficult to cut with spinning or reciprocating blades from power tools.

Sanding or Grinding the Resin

While not really cutting, resin sanding or grinding epoxy resin with power tools is an effective way to remove excess resin from your project. when you are sanding or grinding you are using an abrasive material to wear away the epoxy resin, the coarser the abrasive material the more epoxy resin is removed.

Grinding is far more aggressive than sanding, so be sure to not use to much pressure or you might grind a gouge out of your work surface.

When you sand or grind you need to gradually use a less coarse abrasive to remove scratches and gouges made but the previous grit. this method of cutting also works fantastic for flattening a project before polishing.

Grinding and sanding epoxy resin is by far the messiest way to cut resin so be sure to wear a respirator or dust mask and safety glasses.

You must also work in a well ventilated work area.

Power Snding Resin

Drilling Into Epoxy Resin

You can use a drill bit to cut into cured resin to create a hole in your project. start with drilling a small hole and gradually increase the size of the hole. be sure to not drill too close to the edge of a thin project otherwise, you run the risk of cracking the cured resin.

Make sure that when you drill into it the epoxy is fully supported. It is also worth your time using painter’s tape to protect the area around where you plan to drill this will help prevent the cracking of your workpiece.

Cutting Resin in a CNC Machine

A CNC machine is a type of computer-controlled rotary cutting machine that will cut through material with precision. When cutting resin, it is important to use the proper settings on the machine so that the material does not chip or break. The following tips will help you get the best results when cutting resin with a CNC machine.

First, make sure that the cutting bit is sharp and clean. A dull bit will cause the resin to chip and break, so it is important to have a sharp one. Second, set the speed of the machine according to the thickness of the material. If the material is too thick, the machine will not be able to cut through it without chipping or breaking it. Third, use a lubricant such as WD-40 on the cutting bit before beginning to cut.

However, using a CNC machine is an advanced method not suitable for beginners as the equipment is expensive and there is a large learning curve to go with the high price.

Cutting Resin with a Dremel Tool

For small precise cutting, a Dremel tool is perfect. A Dremel is a compact and powerful rotary tool used for all kinds of art, craft, and hobby projects. A Dremel is not a CNC machine and it does not cut in three dimensions. However, for small intricate cuts on resin models, it is the perfect tool. The Dremel is also a great tool for cutting off excess resin from models.

It has a variable speed dial that allows you to make very fine cuts with little effort and it can be used with small bits for more intricate work. The Dremel is a very common tool that can be found in many hardware stores. A Dremel will also work with a variety of different-shaped bits, so it is possible to use a Dremel for more than just cutting resin.

Cutting Resin with a Router

A router Is similar to a large Dremel tool with a round base. A router typically has a larger cutting bit that moves in a circle, but it can also be used with bits like the Dremel.

The router is much larger than the Dremel and it requires more power to operate, so it cannot be considered for smaller models. A router is ideal for larger models, whereas a Dremel would be too small to operate.

Cutting Resin with a Circular Saw or Table Saw

If you’re working with epoxy resin, you may need to cut it into pieces for your project. You can do this easily with a circular saw and a straight edge. Here’s what you need to know to get the job done right.

When cutting epoxy resin, it’s important to use a blade that is designed for cutting plastics generally these blades have more teeth and smaller gullets (a gullet is a scooped-out section between a blade’s teeth). This will help ensure a clean, smooth cut.

You’ll also want to make sure that the blade is sharp so that it doesn’t chip or break the resin. There are a variety of different saws that use a circular blade, for instance, a track saw that runs along a track to create a straight cut and a table saw which has a variety of different attachments and fences to create a straight cut.

Table saw that has cut epoxy resin

Cutting Resin with a Band Saw

Band saws are designed to cut through hard materials, and they can do so quickly and easily. That means less time spent struggling with your project, and more time enjoying the finished product.

Plus, band saws create clean, straight cuts and curved cuts – perfect for when you need precise results. So if you’re looking for the best way to cut epoxy resin, a band saw is a very versatile tool.

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How to Avoid Mistakes When Cutting Epoxy Resin

When working with resin mistakes can be costly and destroy the entire project, therefore, if you want to avoid making costly mistakes and make a clean cut there are some measures that you can take.

The first method is to use sharp blades to cut your material.

The second is to use painter’s tape around the area you intend to cut this will support the edges and cutting area to prevent chips and cracks and also allows you to make nonpermanent marks on the project.

Finally, always wear safety glasses and a dust mask when using a saw blade to cut hard materials like epoxy resin,

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