So I went out to HD and bought a 12x24 piece of lexan (which was only a few more bucks than the acrylic) to protect my LEDs.

whats the best way to cut the sheet?

I cut it with a high speed dremel and the new twist and lock cutting disc.

I found that the metal cutting blades cut it better than the plastic cutting discs.

A fine toothed table saw blade should work too

Tablesaw with as many teeth as you can get

I tried once with a dremmel tool myself and it melted it beyond belief... what is the secret to doing it with a dremel and not melting the lexan ?

just about anything it cuts like butter i used a cheap jig saw...

hand saw
mitersaw
tablesaw
etc........

honestly i would not use a dremel to cut it...

theres much better tools for something like this

I have tried my hands at it a few times with no luck, but the same as posted above... I need to figure something out to do it for my latest LED project...

I don't have a table saw... but I do have a dremel tool

You can use the dremmel but don't use the cutting discs buy a rotozip tile bit about 8 bucks at home depot and use the router top or the circle cut top.

Then draw your line and place your dremmel on the line and c clamp
down a flat edge board against the dremmel to make your cut straight. I actually use a drywall t ruler.

The table saw is obvously your better option but a dremmel will be fine seeing as a table saw is 150 bucks and a goog carbide blade another 30-50
any questions shoot me a pm

I have a much easier solution. Go back to HD and get a sheet of 1/8" acrylic, and a scoring tool (right above the acrylic). Use a straight edge to score a line a few times, then place the score line on the edge of a table and snap it off. Clean edge, minimal work.

You can also score it with the back side of a razor knife. The dull side for the tired folks. Then snap it. But if your planning on doing this for cemented projects beware. B/C. it leaves a rounded edge thats not suitable for a strong bond.