Bakelite is the common name for phenolic resin, which was one of the first mass-produced plastics. Although it was once a mainstay in low-end jewellery, today it is most commonly used in laminate countertops and scientific laboratories. The strength and its superior non-porous nature make the Bakelite a perfect choice for these two uses. However, the same attributes that make Bakelite desirable also make cutting it a challenge. There is a tendency for Bakelite to splinter, but the use of a specific type of saw blade or drill bit will greatly improve the chances of a clean cut.
Mark off your cuts on the Bakelite with the non-permanent marker.
Put on the safety goggles and dust mask.
Drill a pilot hole in the Bakelite with a diamond-tipped drill bit if you are making interior cuts. If not, skip this step.
Set the Bakelite on a raised cutting surface such as two sawhorses or wooden blocks.
Rip the Bakelite with the diamond blade on the circular saw using the straightedge line as a guide.
Clean the edges of the cut with an alcohol-based cleaner to remove any remaining resin dust.
Tip
For smaller cuts you can use a Dremel tool with a diamond or carbide saw. Diamond blades cut the Bakelite very well but in a pinch a carbide blade will do. If your blade has trouble cutting through the entire depth of the Bakelite, try running three or four shallow passes instead.
Warning
Always wear safety goggles and a dust mask while cutting any resin product. The dust can irritate the eyes and lead to long-term lung problems. Never score Bakelite; the scratches will be permanent.