Sue, John and I can both be right. If you want to really find some boring physics and engineering projects, try figuring out how a saw blade works in various materials. The number and shape of the teeth of a circular saw blade have a lot to do with how the blade performs in different materials. My experience is that if I feed too fast with some blades, the blade catches and breaks the plastic/polycarbonate with a break line that comes out in a "V" shape on one or both sides of the cut and runs for about 2". I would usually use a 10" 24 tooth blade with a wide tooth pattern and a big rake angle and gullet.
John probably uses a blade with more and smaller teeth, and like you on the jig or scroll saw, his saw blade tends to melt rather than remove chips. He is sure right that you might want to practice some small cuts and match the feed speed to the material and blade. While plastic supply houses may be anxious to sell you a particular blade or drill, you really can cut this stuff with about anything if you work at it a bit.
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