How should a hole be drilled in Plexiglas to avoid damage when the drill breaks through to the underside?

When drilling holes in Plexiglas, backing up the plastic with a piece of wood is crucial for preventing damage when the drill bit breaks through to the underside. Plexiglas is a type of acrylic, which is prone to cracking or chipping if there is no support when the drill exits the material. The wood serves as a solid backing that absorbs the energy of the drill bit as it comes through, significantly reducing the risk of splintering or delaminating the Plexiglas surface.

Using a specialized drill bit can enhance the drilling process, but it does not address the issue of potential damage when the bit exits the material. Drilling at high speeds might increase efficiency but can lead to overheating and melting of the acrylic, further increasing the risk of damage. Drilling from both sides may seem like a solution, but it is often impractical and may not prevent chipping if the bit encounters any irregularities during the process.

In summary, providing a supportive backing with a piece of wood offers the best protection for the integrity of the Plexiglas during drilling. This simple yet effective practice allows for clean holes without damaging the material.