Hi Guys, I cut even curved polycarbonate with 36-teeth-per-inch fine metal cutting blades in my saber saw. I use Bosch brand, which are available in packs of 4-5 from Lowes. The edges come out almost polished with no roughness or "heat boogers" (technical term). When you're done you just run your fingers along the edges and all is clean. The keys are: (1) the very fine tooth blade and (2) cover the foot of the saw with some tape and just glide the saw over the plastic without pressing down so as not to scratch or mar the plastic. Also, keep the protective film on to keep from scratching the plastic.
Mark Clapp