Opaque stained glass can hide small flaws until a cut exposes them. Check both faces under angled light, then mark the line with a fine-tip marker.
Wear safety glasses with side shields; tiny chips can spring farther than expected.
NIOSH reports that about 2,000 U.S. workers seek medical treatment for job-related eye injuries each day. That figure covers workplaces, not hobby studios, but it is a useful reminder to protect your eyes.
Keep the sheet flat on a clean, stable surface. Score once with steady pressure, using a glass cutter suited to the material. A shallow, continuous score is better than repeated passes.
I still find it tempting to press harder when a line looks faint. Usually, that makes the break less predictable.
Use running pliers to open the score gradually, keeping your hands clear of the edge. For small curves, remove modest pieces with grozing pliers rather than forcing a long break.
Grind edges with water, following the tool’s instructions; avoid dry grinding and sweeping glass dust.
OSHA notes that suitable eye protection can prevent or reduce the severity of many eye injuries, often cited at about 90 percent. Treat that as a broad workplace estimate, not a guarantee for glasswork.
Rinse the piece, inspect the edge by touch only after it is clean, and smooth sharp spots before fitting or foiling. The finish may still look uneven. Check it again.