Member since November 2005; Posted by Anonymous on Monday, March 15, 2004 9:42 PM I have used quiet a few different routers and they only way I can see any melting plastic is if the speed is set too high. Hole Saw. To drill a plexiglass, unlike how you bore a hole through metals or stones, you don’t have to puncture the plexiglass, begin to pierce the marked spots slowly. Remember, acrylic and metal have different expansion rates. Joined Sep 24, 2012 Messages 5. This will prevent chipping when you begin to drill into the plexiglass. I don't want to struggle any more, or waste anymore money on this; I've spent enough on case modding for now. Don’t push too hard; you can aim at a speed of 3.5 inches per minute. This will help remove chips and dissipate heat as the hole is drilled. So maybe you could figure a way to melt it. Although I think I might have made the holes too large in them.. Plexi and acrylic drill very nicly. Coolants should also be used for holes greater than or equal to 1/2" in diameter (D ≥1/2"). If you go slowly and gently, the acrylic won't melt or crack. Heat up your soldering gun/iron, and melt the hole (s) in the plastic. The heat and burning is what melted the hole in the plastic. Do not leave the plexiglass in the oven longer than seven to eight minutes, as this can result in melting. Holes for fasteners should be drilled oversized to allow for thermal movement of the Plexiglas. A small bit … Good luck. I'd be worried about using anything larger. Be sure that the drill is variable speed, and work slowly so you dont heat up the plastic and make it start warping/melting. When drilling holes run the drill in reverse at a high speed and the drill bit will melt through it - don't use very much pressure just let the weight of the drill do the work. I cut and do some plastic welding at work and the best thing I have found to cut plastic with is a Roto-zip saw. The wood will help minimize the vibration that causes the plexiglass to crack. Take your time and let it cool often. Friction welding is another way of joining plastic together. Hot bits will melt the plexiglass around the hole. Since Plexiglas® acrylic sheet is an excellent insulator,the surface exposed to the heater may overheat before the rest of the sheet is hot enough for forming. it is quite likely that you will need to make another hole in your life ,, so go out and buy a 3/8 varriable speed reversing drill. Always, use a Plexiglas Drill Bit or regrind your steel bit to a 60 degree included tip angle. This is done by drilling a hole in the plexiglass, then placing the jigsaw blade in the hole. You only wish to soften the plexiglass with heat. The secret is to melt the plastic in the joint so that both melted parts get together, welding themselves. Drill Bits For Drilling Plastic Acrylic Plexiglas Perspex Laminate Smooth Clean No Cracking. JavaScript is disabled. Plexi and acrylic drill very nicly. But anyway, the window is in place, and I know realized that I wanted to put this hole in it. You can pick up a nice pack with assorted sizes at any hardware store. If you are wanting to use some of those premade vents, and cut a whole to place the vent in, you need a holesaw. I prefer the drilled look, imo the melted holes look horrible. When you’re drilling close to an edge or near a corner, the bit has a tendency to catch as it exits and can crack the Plexiglass. More Info Here. It is also hard to control by freehand, so I always use a guide bar clamped to the surface to act as a guide for the saw. Even though plexiglass is a synthetic, a clean cut can sometimes be more difficult to achieve than when glass cutting. I think it's acrylic, or plexiglas anyway - a case window. Electric drill with speed regulator 2. Irregular holes and rough edges could lead to cracking, even months after the drilling occurs. 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