Acrylic sheet (also known as Perspex or PMMA) is an excellent material for lighting panels, displays, furniture, and protective barriers. It’s strong, lightweight, and visually clear — but drilling it requires care. Using the wrong technique or tools can lead to cracking, chipping, or melting.
Acrylic is more brittle than metals or wood. When too much pressure or heat is applied, the sheet can fracture or craze along stress points.
Using metal or wood drill bits.
Drilling too fast or with too much pressure.
Not supporting the sheet properly.
Letting heat build up during drilling.
By using the correct bit, speed, and support, you can drill smooth, precise holes without damaging the sheet.
Acrylic drill bit or modified twist bit (with shallow tip angle 60°–90°).
Variable-speed drill (hand drill or drill press).
Clamps (to secure the sheet).
Scrap wood backing board.
Masking tape (to mark drilling points).
Coolant or water spray to reduce heat.
Step bit for large holes.
Countersink bit for finishing edges.
Protective goggles.
Dust mask.
Gloves (non-slip).
A clean and stable setup ensures a crack-free result.
Leave the protective film on the sheet during drilling to prevent scratches.
Clamp the sheet firmly onto a flat surface.
Place a piece of scrap wood underneath to support the drill exit point.
Mark the drilling position using masking tape — it helps prevent slipping.
Make sure the sheet doesn’t vibrate, as even slight movement can cause micro-cracks.
A standard metal drill bit is too aggressive and can grab or chip acrylic.
| Bit Type | Features | Use |
|---|---|---|
| Acrylic or plastic drill bit | Blunt angle tip and wide flutes | Best for clean holes |
| Modified twist bit | Ground or filed to a 60°–90° tip | DIY alternative |
| Step bit | Gradually enlarges holes | Ideal for large openings |
| Brad point bit | Works for thin acrylic | Avoids slipping |
Tip: If modifying a bit yourself, grind the cutting edge slightly flat to reduce bite and heat buildup.
For thin sheets (2–4 mm): 1,000–1,500 RPM
For thick sheets (5–10 mm): 500–1,000 RPM
Hold the drill perpendicular to the surface.
Start slowly to create a shallow pilot mark.
Gradually increase speed while maintaining light, steady pressure.
Frequently lift the drill to allow chips to escape and cool the hole.
Avoid forcing the drill — let it “cut” slowly rather than “push” through the material.
Excessive heat can melt acrylic or cause stress cracking after drilling.
Drip water or coolant onto the drilling area.
Pause occasionally to allow the material to cool.
Use compressed air to blow away chips and heat.
If using a drill press, you can also spray a fine mist of water continuously during drilling for smooth results.
If you need holes larger than 10 mm, a step drill bit is the safest option.
Cuts gradually in layers, reducing stress.
Prevents cracking from sudden torque.
Leaves smooth, round openings.
Start with a smaller pilot hole (around 3–4 mm) before using the step bit.
After drilling, you may notice light burrs or rough edges.
Use a countersink bit or deburring tool to smooth the edge.
Lightly sand with fine-grit sandpaper (400–600 grit).
For optical clarity, polish the hole edges with a soft cloth or buffing wheel.
Smooth edges not only look professional but also prevent cracks from spreading over time.
| Mistake | Result | Solution |
|---|---|---|
| Using high drill speed | Melting and cracks | Use low to medium RPM |
| No backing support | Blowout at exit | Use scrap wood underneath |
| Applying too much pressure | Sheet fracture | Drill slowly and evenly |
| Using wrong bit type | Chipping | Use acrylic or plastic drill bit |
| Not cooling | Heat stress | Pause or apply coolant |
Patience and control are far more effective than force when working with acrylic.
Kunxin Plastics manufactures optical-grade acrylic sheets that are engineered for easy cutting, drilling, and forming — with excellent durability and visual clarity.
Uniform density for consistent drilling results.
High heat resistance and low internal stress.
Excellent light transmission (up to 92%).
Available in frosted, opal, matte, and prismatic finishes.
Compatible with mechanical and laser machining.
Kunxin acrylic sheets are ideal for lighting diffusers, display panels, protective barriers, and signage, providing both strength and machinability.
Drilling acrylic sheet without cracking requires patience, precision, and the right setup. By using a sharp plastic drill bit, maintaining low speed and pressure, and keeping the material cool and supported, you can achieve clean, professional holes every time.
For projects that demand superior clarity and consistent performance, Kunxin Plastics offers high-quality acrylic sheets designed for smooth machining and long-lasting stability.
Whether for DIY projects or industrial fabrication, Kunxin’s optical-grade acrylic materials ensure strength, precision, and flawless visual results — every time you drill.
