cutting lexan
Having cut lexan for many years, I can say one for sure. These sheets come with masking film or paper, never ever remove them till the last drop of cutting is out. This is the only way you can avoid scratches. As for cutting letters are concerned, fret saw (like your sewing machine, a thin wired saw goes up and down) which is fed into a predrilled hole runs across the sheet and the machinist should hold the letters damn strong as well as turn the sheet to the need of the design as well. (That's why I compared this to a sewing machine). If Lean is cut for machine part, then high speed low feed is the best way out with bee wax as lubricant on to the cutters.
Regards
Chan Luci, Techie
www.custompartsonline.com