How to Drill holes in Plexiglass

Drilling holes in plexiglass doesn’t require professional help; however there is a risk of melting and cracking. But by applying the proper method, one can avoid those common mistakes and prevent ruining the acrylic sheet. So, learning how to drill holes in plexiglass in the proper way can make the task successful.

Plexiglass is a sturdy yet lightweight material that is frequently used for both industrial and housing purposes. It often needs drilling to make the plexiglass sheet usable for a range of applications. But it can melt and crack due to extreme friction and excessive heat during drilling on it. Thus, applying the proper method of drilling is essential to complete the job safely and accurately.

Guides to drill holes in plexiglass

We will discuss an effective and safe method of drilling holes in plexiglass. It’s a user-friendly method and anyone can get benefits from it. Apart from these, the guide included some smart tips for drilling into plexiglass without breaking it.

The tools you will require:

Drilling plexiglass will create flying chips. So wear your safety gloves, goggles, and face mask before starting drilling. Other tools you will require:

• Power drill
• Drill bits
• Plexiglass
• Clamps
• MDF board
• Masking film

Pick the right drill bit

Picking the right drill bit for the acrylic sheet is vital for having a precise hole in plexiglass without cracking it. Using the wrong drill bit can also melt holes in plexiglass or damage the plexiglass surfaces. Choose the drill bit considering the plexiglass thickness and the diameter of the desired hole.

You can buy the typical plexiglass drill bits from any hardware shop or online. Using a step drill bit for plexiglass is also a better method of drilling onto it without it cracking. We recommend you use spiral drill bits as they are reliable for use on plexiglass sheets. It has a special cutting geometry that prevents the breaking or cracking of plexiglass.

Place the plexiglass sheet

Firstly, set the plexiglass sheet on the MDF board. Use masking tape over the plexiglass surface as it will prevent chipping while you drilling a hole.

Mark the spot

Use a permanent marker or a grease pen to indicate the location where you want to drill a hole. Don’t try to create a hole near the edge of the plexiglass sheet as it could encourage the sheet to break out. 

Practice on a scrap sheet

Whether you are a pro or a starting DIY enthusiast, you should practice drilling on a small Plexiglas sheet. It will let you set your hand and mind to creating accurate holes without any hassle. 

Secure the plexiglass

Now secure the plexiglass on a table or workbench with screw clamps. Make sure you have aligned the plexiglass properly before securing it to the MDF. If it isn’t placed tightly, then the plexiglass will start moving because of the vibration of the drill, which may end up cracking. 

Set the drill

At this stage, insert the drill bit and connect your corded drill with power outlet. If it is cordless, then place the battery and ensure it is fully charged. Then, set the rotational speed of your power drill at a slower speed to get an accurate result. A basic rule is, if you want to create a larger size hole, set the rotational speed lower. You can practice speed setting on a scrap piece to ensure the desired setting.

Start drilling on plexiglass

Now set the bit in the center of the mark that you created earlier. Start with a slower speed and keep your eye on the drilling position.

Adjust the rotational speed

Rotational speed plays a vital role in the quality of the hole in plexiglass. A feed rate of 3.5 inches per minute is ideal for having a smooth hole surface. The plexiglass sheet will start producing plastic chips while drilling on plexiglass. You can set the correct rotational speed by checking these shavings. 

If you find flaky chips or rough holes, then lower the rotational speed. Conversely, if you feel the drill is overheating, increase the rotational speed. The drill bits’ friction is also liable for creating extreme heat which leads to cracking the plexiglass. To prevent such a situation, periodically apply water to the plexiglass sheet while drilling.

Don’t drill continuously

It is especially recommended for drilling plexiglass sheets that are thicker than 5mm. Doing so will create overheating and encourage the sheet to crack or break out. So if you want to drill holes in plexiglass without breaking them, then drill for a short time and remove the chips from the hole. Besides, keep applying water between the intervals of drilling.

Finish up

Once you have successfully drilled a hole in the plexiglass, clean the dust around the hole using a wet rag. Then remove the masking tape and the marks you have created. 

Other drill bits that you can use on plexiglass

Plastic Drill Bits: This drill bit has 90-degree point ground flukes and can drill through the plastic. It scrapes the plexiglass away coat by coat. Plastics drill bits are available in a range of diameters, so you can create the desired diameter hole in plexiglass. These drill bits are available in both hardware stores and online.

Diamond Dusted Drill Bits: This bit is suitable for drilling through hard plastic. It has a diamond dust coating outside of the bit which retains its cutting edge sharpness for a long time. The diamond dust drill bit has 60-degree points and a 0-degree rake. This drill bit is ideal for drilling multiple layers of plexiglass. These aren’t commonly available at hardware stores. So you may need to purchase it online.

Modified Drill Bits: You can use the regular drill bits to drill a hole in plexiglass only if you customise them. To modify the drill bit, you have to grind the small flats on the cutting edge of the bit. 

Doing so will help the bit scratch away the plexiglass. Once properly modified, the drill bit, you will notice two consistent spiral ribbons of plexiglass releasing from the drilled hole.

Tips for drilling holes in plexiglass without breaking it

To drill a hole into plexiglass properly, control the drill speed. Running the drill at a faster speed will heat the bit more quickly. As a result, it will melt the plexiglass sheet around the hole. Conversely, drilling slowly and retracting the drill bit from the hole regularly will keep the bit cool. Another important tip is to create a larger hole than a screw if you are drilling a screw hole. It will prevent the screw from convincingly grabbing the plexiglass and offer enough room to expand. Other tips are:

• Recheck the screw clamps regularly while drilling into the plexiglass. It is essential to keep the plexiglass in place and ensure precise drilling.
• Use the right drill bit as it determines the quality of the hole in the plexiglass.
• If the drill bit sticks on the opposite side, don’t continue drilling. Turn the plexiglass sheet, secure it and start drilling on the other side.
• If there are no screw clamps, hold the plexiglass sheet firmly with your hand so it can’t move.
• Don’t use any glue or sticky material to place the plexiglass on the MDF.

FAQs on How to Drill holes in Plexiglass

Final words

In the end, hopefully, you have learned how to drill holes in plexiglass successfully. We have explained the method in details, so you can apply it properly in practice. So fix that safety issue first and then you are ready to go ahead.

Once finished with the drilling work, apply some care to remove the plexiglass from the work table so it doesn’t get damaged. Finally, if you don’t have previous experience, practice a scrape sheet that will boost your confidence.