What should be done when drilling a hole in Plexiglas to avoid damage during breakthrough?

When drilling a hole in Plexiglas, backing up the plastic with wood is the recommended approach to prevent damage during the breakthrough process. Plexiglas, being a type of acrylic, can become brittle and prone to cracking when force is applied. By supporting the material with a wooden backing, you provide additional stability and absorb some of the impact that occurs when the drill bit exits the Plexiglas. This method reduces the risk of chipping or cracking around the edges of the hole, allowing for a cleaner and more precise finish.

Utilizing larger drill bits, while it might seem like a way to prevent damage, would not effectively address the issue of crack propagation. Drilling quickly can lead to overheating of the material, which may also contribute to cracking. Using lubricant can be helpful in reducing friction and heat but does not specifically tackle the challenge of managing stress during the breakthrough phase. Therefore, supporting the Plexiglas with a solid backing remains the best technique to ensure integrity and quality of the drilled hole.