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A free scan shows the junk files, broken settings and background clutter dragging Windows down - then fixes them in one click.Free scan · Windows 10 & 11For acrylic sheet, choose a sharp bit ground for plastic: its lower-angle geometry scrapes instead of aggressively cutting, helping reduce chips and cracks. For many other plastics and small holes, a sharp high-speed-steel (HSS) twist bit is generally sufficient. The right choice still depends on the plastic, hole size and depth, and whether you need a clean finished hole or just a rough opening.
Choose the bit for the plastic
Acrylic sheet
Acrylic (PMMA) can chip or crack under the aggressive cutting action of an unmodified metalworking bit. For cleaner holes, use a purpose-ground plastic or acrylic bit with a sharp edge and geometry designed to scrape the material. ACRYLITE generally recommends a 90° tip for its sheet-drilling operations; 60° tips are also used, particularly for holes at least 1/2 inch in diameter. Its guidance gives a typical helix angle of 15–30°. ( ACRYLITE drilling guidance)
PLEXIGLAS likewise recommends special spiral bits whose edges scrape rather than cut, to reduce cracking and breakout. For acrylic, its machining guidance lists a rake angle of 0–4°, point angle of 60–90°, clearance angle of 3–8°, and feed of 0.1–0.3 mm per revolution. These are manufacturer parameters, not a universal specification for every bit or setup. (PLEXIGLAS drilling instructions; PLEXIGLAS machining guidance)
TAP Plastics’ PlasDrill is one documented product example: the company describes it as an HSS bit designed for acrylic, plexiglass, perspex, and polycarbonate, and recommends using it exclusively on plastic. That is a manufacturer description, not an independent product ranking or a guarantee of hole quality. (TAP PlasDrill Bits)
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Other plastics
“Plastic” covers materials with different drilling behavior, so do not assume acrylic-specific geometry or settings apply to every sheet or part. Boedeker says HSS twist drills are generally sufficient for small holes in plastics, and gives a broad range of 1/32 to 1 inch (about 1–25 mm). It recommends frequent withdrawal to clear swarf and notes that point geometry varies by plastic type. Check the material maker’s instructions, especially for filled, brittle, or notch-sensitive plastics. (Boedeker plastic drilling guidelines)
Match the bit to the hole
Bit choice changes with hole diameter, sheet thickness, depth, and the finish required. A standard or plastic-ground twist bit is suited to many smaller holes; other tools can make sense for thin sheet or larger openings, but they are not interchangeable for every material.
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| Tool | When it may fit | Important qualification |
|---|---|---|
| Plastic-ground spiral bit | Acrylic sheet where reducing cracks and breakout matters. | Use geometry appropriate to the hole; ACRYLITE generally recommends 90° tips and also notes 60° tips for holes at least 1/2 inch. (ACRYLITE) |
| HSS twist bit | Many small holes in plastics other than acrylic, or general plastic drilling when the material maker permits it. | Boedeker’s broad guideline covers 1/32–1 inch holes; point geometry varies by material. (Boedeker) |
| Step drill | Thin sheet or a stepped opening within the tool’s range. | ACRYLITE lists step drills for sheets up to 0.118 inch (3 mm) and holes from 1/8 to 1/2 inch; it calls for strong backing. PLEXIGLAS also describes step drills for thin sheet. (ACRYLITE; PLEXIGLAS) |
| Fine-tooth hole saw | A large, rough passage opening in thin material. | PLEXIGLAS describes this for large holes in thin sheets; it is not a substitute for a finishing bit when a smooth, accurate hole is required. (PLEXIGLAS) |
| Conical bit | Thin or corrugated sheets where a tapered opening is appropriate. | PLEXIGLAS lists it as a conditional alternative, not a universal choice. (PLEXIGLAS) |
For a large, rough opening, a hole saw may be more practical than enlarging a small hole with a twist bit. For a finished hole, choose a tool that matches the required diameter and finish, and support the sheet so the tool does not pull material away at the exit.
Set up the sheet to limit cracking and breakout
- Support the work. Lay the sheet on a firm, level base and clamp it securely. Place a sacrificial backing board beneath a through-hole so the bit exits into support rather than unsupported material. PLEXIGLAS recommends clamping sheet to a firm base and keeping the masking film on while drilling. (PLEXIGLAS; ACRYLITE)
- Start steadily and avoid forcing the bit. Keep the drill aligned with the sheet. Reduce feed shortly before the bit breaks through; pushing hard at the exit can encourage breakout. (PLEXIGLAS)
- Clear chips from deep holes. When the hole depth exceeds the bit diameter, withdraw the bit periodically to remove swarf. ACRYLITE recommends peck drilling at this depth and generally recommends coolant when depth exceeds bit diameter or hole diameter is at least 1/2 inch. Follow the particular plastic maker’s cooling guidance for thick, deep, or large holes. (ACRYLITE; Boedeker)
- Deburr gently if needed. ACRYLITE lists a zero-flute countersink for deburring. Use a light touch rather than trying to remove material aggressively from a brittle edge. (ACRYLITE)
Adjust speed and feed by what the hole tells you
There is no universal RPM for drilling plastic by hand. ACRYLITE says manual work should use slower speed and feed than automated or CNC drilling, with bit diameter, sheet thickness, and cooling all considered. Its published acrylic table varies surface speed and feed per revolution by diameter and specifies lower surface speed for larger bits. One PLEXIGLAS machining example uses a 25 mm drill at 510 rpm under its stated conditions; treat that as a manufacturer example, not a general hand-drill setting. (ACRYLITE; PLEXIGLAS)
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- FOR BATH, KITCHEN & CRAFTS: Ideal for drilling bathroom tile, mounting mirrors, cabinets and grab bars, or making drainage holes in ceramic pots. For tile and glass, use painter's tape to stop slipping, drill slowly & use water cooling to reduce chipping
- 3-FLAT SHANK FOR STANDARD DRILLS: Anti-slip shank fits standard keyed or keyless 3-jaw chucks on corded, cordless and hand drills, plus drill presses for a wobble-free hold. Use rotary mode only, Not for hammer drills, impact drivers or SDS rotary hammers
- Chipping: ACRYLITE says that if the material chips, the feed rate is too fast and must be decreased. (ACRYLITE)
- Melting: ACRYLITE identifies melting as a sign that feed is too slow or RPM is too high. Stop and adjust rather than continuing to generate heat.
- Poor chip removal: Withdraw the bit periodically to clear swarf, particularly in deeper holes.
Quick choice guide
- Drilling acrylic sheet: use a sharp bit ground for plastic, with geometry intended to scrape; support and clamp the sheet.
- Drilling a small hole in another plastic: an HSS twist bit is generally a reasonable starting point, subject to the material maker’s guidance.
- Drilling thin sheet or making a larger opening: consider a step drill, fine-tooth hole saw, or conical bit only where the sheet thickness, material, and required hole shape suit that tool.
- Drilling deeper than the bit diameter: withdraw periodically for chip removal and check the material maker’s cooling recommendations.
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