Drilling Acrylic Sheet Guide

Drilling Acrylic Sheet with a Step Drill – Simple DIY Guide

This quick guide shows you how to drill clean, crack-free holes in acrylic using the Frost 4-12 mm HSS Spiral Step Drill (available at Bunnings). One tool covers every hole between 4 mm and 12 mm—ideal for weekend projects.

Quick tips:
• Clamp the sheet flat on a scrap MDF board
• Run the drill at slow–medium speed (600–900 RPM)
• Use light, steady pressure; let the step drill do the work
• “Peck” out every 5 mm depth to clear chips and keep cool
• Finish edges with a zero-flute deburring tool for a crystal-clear bevel

1 · What You’ll Need

Frost 4-12 mm HSS Spiral Step Drill (Bunnings I/N 0170878)
Variable-speed drill press or quality hand drill (0–1 200 RPM range)
Piece of scrap MDF or acrylic as a backing board
Clamps to stop vibration and keep holes square
Low-tack masking tape for marking hole centres
Cooling option: compressed air or a light water mist spray bottle
Optional: P&N HSS Deburring Tool 5-10 mm for flawless chamfers

2 · Step-Drill Settings

Target Hole Ø	Recommended RPM	Peck Depth	Coolant Tip
4 – 6 mm	800 – 1 000	5 mm	Usually not needed
7 – 9 mm	700 – 900	Every 5 mm	Air blast helps
10 – 12 mm	600 – 800	Every 3 mm	Mist with water

3 · Step-by-Step Drilling

Mark & Tape – Cover the drill spot with masking tape and mark the centre.
Clamp Securely – Lay the acrylic on the MDF backing board and clamp both edges.
Pilot Dimple (Optional) – Touch the centre with a 2 mm twist bit or the step-drill point for easier starting.
Drill Halfway – Set RPM from the table, apply gentle pressure, and stop when the step point just shows on the far face.
Flip & Finish – Turn the sheet over, align the point, and drill from the second side until you feel the two cuts meet.
Deburr – Lightly touch the hole with the zero-flute deburring tool or 600-grit wet-and-dry to polish the chamfer.

4 · Common Hiccups & Fixes

Melting chips? Lower RPM, use air or water mist, and peck more often.
Chips on exit? Always drill halfway from each face and keep the backing board tight.
Oval hole? Clamp closer to the hole and slow the feed—flexing sheet can widen the cut.

Safety first: Wear eye protection, secure small off-cuts in a vice, and keep swarf away from open flames—acrylic is flammable if overheated.

Need Acrylic Sheet or Custom Cuts?

Warlond Plastics stocks clear, tinted & coloured acrylic in full sheets or cut-to-size panels, shipped Australia-wide with fast turnaround. Browse our range → or contact us for friendly advice.

Disclaimer: This information is provided as a general guide only. Always follow the instructions and safety recommendations supplied with your tools and materials. Warlond Plastics accepts no liability for damage, injury or loss arising from the use of this guide.