Ok guys, how to create perfect circles from styrene sheets? What materials to use? Any alternatives? The diameter is about less than .5 inch.

I know Exacto does or use to make a "Circle Cutter". I never tried it, but i was thinking of takinga brass tube and sharpening the edge and using it as a puch to make circles.

If you have a decent compass (not the 2 dollar one with the golf pencil stuck in it) cutting circles is pretty easy. Just put points in both legs of the compass, set your diameter and use the second point, where the lead would normally be, to scribe your circle in sheet styrene. You should be able to pop the circles right out. Done this several times.

HTH,

Shaun

Pete, I have used sharpened brass tubing as a punch to make styrene discs about 1/8th inch in diameter. Worked pretty well in thin sheet.

Depending on the size of the circle and the thickness of the media to be cut I use both of the above mentioned systems...
Ciao

Ok thanks! Will do. Thanks for the tips!

Well, once again being "Mr. CHEAP" .....
I've been using a plain old plastic circle template, goes from 1 inch down to 1/8 inch. I simply have a sharpened needle, cut very short, so there is no flexing of the needle clamped into an old exacto handle (the kind the is split into 1/4's.)
I simply allow the needle to follow the template and gently engrave the circle, eventually to cuts through the plastic card.

Keep the needle sharp, and straight up and down, and remeber that due to the shape of the needle it will cut the circle a tiny bit smaller than size of template hole.

Once you get the engraved line deep enough, you can simply follow through with a new #11 blade. I've been doing it this way for years, and end up with either the hole I want, or the disk I want. Light pressure, and letting the needle lightly scribe through the plastic card. I do card from .005 up to .20. Haven't had the need for any thicker, but probably would work, just taking a little longer.

I also use the same needle to act as a center punch when I need to drill holes.

Depending on availability where you are, try collecting empty shell casings in various calibers and use them as punches.

Art