How to Cut Corian Countertops

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  • 3-6 hours
  • Intermediate
  • 20-250
What You'll Need
Fine-tooth circular saw
Router w/ straight bit and fence (optional)
Belt sander w/ 50-grit sandpaper (optional)
Masking tape

Corian countertops are a unique material, developed by DuPont scientists in 1967. The surface is made from an acrylic polymer and an alumina trihydrate mix that creates a beautiful look and comes in many unique designs and colors. These synthetic materials are quite durable and easy to clean and maintain. Additionally, they can add significant value to your home, as they are widely sought after in high-end kitchens.

Installing any kind of new countertop in your kitchen, no matter the material, is a surefire renovation idea that unfortunately adds up to a big investment when you tack on installation costs. To put new counters in, you will need to know how to secure them in place, but also how to measure and cut the pieces in the dimensions you need.


Place the Corian on sawhorses, upside down. Measure carefully for the countertop space and mark the cut lines with a pencil or grease pencil. Do not use markers on Corian as you risk making a permanent blemish on a pricey material.


Cut slowly, with light pressure on the blade. You’ll want to cut Corian in a similar fashion to very hard wood, making several passes that cut off a small amount with each pass.


You can choose from a variety of tools to make the cuts you need for your kitchen. If you’re inexperienced with power tools or feel uneasy about making the right cuts, feel free to enlist the help of the pros.

Circular Saw

You can use a fine-tooth circular saw to cut Corian, a carbide blade with 80 to 100 teeth being ideal. If you have fewer teeth (for example, a standard 40-tooth blade), use masking tape on the Corian to reduce splintering.


Another good tool for cutting Corian is a heavy duty router with a straight bit and a fence. Again, cut in several passes for the safest, cleanest cut.

Belt Sander

For small cuts, you may find a belt sander with a 50-grit sandpaper will work down 1/8 to ½ inches fairly quickly and with more accuracy than cutting. This is a particularly useful technique if you have uneven walls that you must accommodate. If you buy sandpaper in a set that gives various grits, you can keep the finer stuff (220-grit) for later days and use it buff light scratches out of the countertop.

Corian produces a beautiful and durable surface that’s sure to appeal and add value to your home. If you take the proper care and use the right tools when cutting it, you will produce a beautiful product without breaking the bank in installation fees.