Drilling lexan

[Cajun Kid]

You just need to grind some reverse rake on your drill bit so that it is more of a scraping action and won't grab and crack the plastic.

Rob,

If he adds rake or alters the bit he will have to run in the Modified or Altered Class   

Charles

[robfrey]

Very funny Charles. LOL! Maybe he could get a rules variance?

[754]

Its called Negative rake..

 I sorta doubt point angle is critical, rake is most important, and flute helix should not matter at low material thickness..

[Dean Los Angeles]

Craftics sells tools for working with plastic.
All of their drills have 0 rake. Keeps the drill from biting in.
http://www.craftics.net/ShowItems.aspx?Category=132&ParentCategory=87

Lexan machines very well. If you can put it in the drill press you have better control over the speed. Sandwiching the Lexan between two pieces of thin aluminum and drilling through the stack will give you better results and hole finish.

If you have an edge that shows, sand and polish to a good finish then give it a wipe with MEK. Experiment on scrap and you can get a really clear edge.

[saltfever]

All good rules so far. But the number one rule is never, never, ever drill into cold Lexan!    Set it out in the sun for a while or warm it some other way but make sure it is warm.

[JimL]

I've always had great luck melting through with a round/pointed fine burr in a Dremel tool....turning FAST.  Makes a wonderful clean hole, and easy to control.  Never cracked one yet.

JimL

[saltfever]

Excellent link. This is how its done and should help you avoid a lot of expensive tears. It answers a lot of questions. 

http://link.brightcove.com/services/player/bcpid1431564069?bclid=1432781645&bctid=19802261001