Plexiglass, also known as acrylic, is a material that is often used in place of glass. It is a light, yet durable, polymer that is used in the construction of commercial and residential buildings, for projects such as safe enclosures, furnishings, and window panes.
Why is Plexiglass Used So Often?
You may be wondering why many people find plexiglass to be an incredibly useful material in a range of applications. But the reason is not so far-fetched: it is a lighter alternative to regular glass and can serve as an economical alternative to polycarbonate in areas where strength is not of extreme importance. When compared to other clear plastics, Plexi & acrylic glass is scratch resistant.
Using laser cutting technology, plexiglass can also be cut into very fine shapes as concentrated laser energy causes the material to vaporize. In fact, if optical clarity is a crucial factor, you should consider using plexiglass for your residential or commercial project.
Unfortunately, the durability of plexiglass could be put to test under certain conditions, especially as they scratch easily. Plexiglass sheets have relatively low strength and impact resistance. So, if forced, plexiglass could brittle and even crack. You must exercise proper care when drilling through it.
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Now, given its potentially brittle nature, how do you drill holes in plexiglass without causing cracks?
This article discusses a number of safe and easy ways you can apply when drilling your plexiglass panels in order to avoid cracks.
- Get the Right Tools
Though regular plexiglass drill bits can be used to drill wood and metal, it will crack plexiglass. But you should rather get plexiglass-specific tools that have been designed for this purpose. If you can’t plexiglass-specific drills, you can still use a regular drill that would run at a speed of around 500 to 1000 RPM, in addition to plexiglass drill bits.
Plexiglass drill bits are geometrically structured in order to allow them easily puncture into acrylic materials. Asides the power drill, you would also need masking tape to be placed on the acrylic sheet as well as the underlying support, grease oil or permanent markers, spray lubricant to make the drill a bit wet, and a piece of wood. Equipped with these tools, you can perfectly drill into the plexiglass.
- Protect Yourself First
Yes, it is safety first! As much as it is important to have a good knowledge of the tools you need before you start drilling, it is equally vital that you protect yourself. This is because the small acrylic chips can easily fly off the tool while you are drilling, so you need to wear safety goggles to prevent any health hazards. You may also use a face mask for this purpose.
- Prepare for Your Drill
When drilling into metal or wood, just marking your spots and starting off the drilling process once you’re protected may be proper, but drilling into plexiglass requires a few more preparations.
As noted earlier, you’d need a piece of wood – this would serve as a platform where the plexiglass should be placed. So, you can use a block of scrap wood for this purpose since you may be drilling through the wood, but you should ensure the wood is hard enough to protect your plexiglass from cracking. A piece of scrap plexiglass sheet or Medium Density Fireboard (MDF) can also serve this purpose. Also, use spring clamps to keep the plexiglass in place so that they remain stable while you drill.
While preparing for your drilling project, ensure you do not put a hole at the edge of the piece of plexiglass, as their edges easily chip off when drilled.
But before your drilling begins, mark the spots you want to drill holes into using a marker or grease oil, to prevent chipping.
- Using the Drill
It is now time to drive your tool into the plexiglass. Depending on the drill you’d be using, insert the charged battery or plug it in and turn it on. You do not have to puncture through the plexiglass as you would do with stones or metals. Start by slowly piercing the marked spots; aim at applying a speed of 3.5 inches per minute, so you do not push through the material too hard.
At medium speed, the plexiglass chip would break off immediately; if it doesn’t, then your drill is too slow. Allow the drill to sink through the plexiglass sheet itself; ensure you do not press too hard on it. Once your drill is almost through the acrylic material, support it by allowing it to run into the scrap wood you used as an underlying platform.
We recommend you start a pilot hole of at least half the diameter of the intended hole, then gradually increase it to the next size of the bit drill until you get to the right hole size. For instance, to drill a half-inch hole, you can start a pilot hole by making a ¼ bit drill for a start before increasing it to a ½ bit drill.
Drilling into a plexiglass sheet can cause friction which produces intense heat. This heat will stress the plexiglass and would result in cracking, causing lots of plastic chips around the hole, especially if the plexiglass sheet is thick. So, while drilling, we recommend you take a break on occasion to clean up the plastic chips around the hole, so you can have a clearer view of your job. You should also drive your drill little at a time so the shavings in the hole can be removed.
During this break, also apply some spray lubricant to add a bit of moisture to the drill. This does not only prevent the heat caused by the friction of the drill from damaging the plexiglass, but protects it against chipping, cracking, and melting.
Once you’re done with drilling the hole, do not turn off the drill immediately, but allow it to continue turning as you take it off the hole. Also give the sheet some time to cool, then clean its surface for a nice finish.
What Kind of Drill Bits Should You Use?
As noted earlier, specialty drill bits are ideal for drilling holes through plexiglass, though traditional drill bits can be altered to work with it too. Here are three options you could consider:
- Plastic Drill Bits
Plastic drill bits are available in a range of diameters at home improvement outlets. With a 90-degree point and 0-degree rake, plastic drill bits are designed to shave plastic acrylic material layer by layer.
- Diamond Dusted Drill Bits
These types of drill bits are designed to drill through hard plastics. The diamond dust coating at the exterior of the bit ensures it has a very shard cutting edge. They come with 60-degree points and 0-degree rake, and are good for stack drilling or drilling through several layers of plexiglass.
- Modified Drill Bits
Traditional drill bits typically used for drilling metal can be modified to drill plexiglass. Modify traditional bits by grinding the small flats on the cutting edges of the drill bit. This will allow the drill bit to scrape layers of plexiglass away rather than grab or fragment the material.
Final thoughts
This article has discussed how you can effectively drill holes through plexiglass safely – without any cracks. You must exercise some care when drilling through a finished material like plexiglass.
Ensure you control your speed while drilling. Go slow to prevent intense heat from melting the plexiglass around the hole. Always have important items like grease oil to keep the plexiglass surface moist.
To ensure your safety and avoid damaging the whole sheet during the drilling process, it would be great to practice drilling through smaller pieces. Once you are confident with smaller pieces, you can now take on larger plexiglass sheets. This would be especially ideal if you have no prior experience drilling through the acrylic glass and ensure you apply maximum care during this DIY project.
