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Best tool for cutting a neat circle in 1mm plastic?

post #1 of 5
Thread Starter 
Following on from this post http://www.overclock.net/t/1589545/fitting-a-momentary-military-fighter-pilot-pc-toggle-switches a kind guy on another forum has sent me a load of 1mm white plastic card which I need to cut two 30-35mm disks and then cut a 13mm hole in the centre.
This tool in the image does the centre hole very well so looking for a cheap solution to cutting the disks out. I do have something similar to this http://www.ebay.co.uk/itm/Handy-Adjustable-Wood-Plasterboard-Spot-Hole-Saw-Circle-Drill-Bit-Cutter-DIYTool-/261589322534?hash=item3ce7f04b26:g:r5cAAOSwZG9Wk0PY or is there something else I should be looking at. As it is likely to be a one off job I do not want to spend to much on the tool.

post #2 of 5
You got pretty close. A simple hole saw with a pilot bit would do fine. Be sure to have a spray bottle handy and douse it with water while you're cutting or you'll melt and temper the acrylic.

Example
http://www.makita.co.nz/accessories/item/drilling-55

All bi-metal saws will work but I'm sure you'll be able to find one that specializes in hard plastics, but for the longevity and range of use I recommend a bi-metal.
post #3 of 5
I'm confused, do you want to cut a bunch of little 1mm discs or a bunch of 1mm holes? I'm not sure how you would do discs, but with holes dont spend a ton on some tool, just get a 1mm drill bit and call it good.
post #4 of 5
If your tolerances aren't too tight, use a drill to make the small hole. Sandwich the plastic between two thin pieces of wood to cut down on burring. Then use a leather hole punch to cut out the disk itself.

Since you are doing so few, you may be able to cut the disk out around the drilled holes using shears and a file to clean it up.

These two washers are already pretty close to the size you want:

http://www.mcmaster.com/#90295a494/=114pcg0

http://www.mcmaster.com/#90295a494/=114pcg0
     
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post #5 of 5
Thread Starter 
Quote:
Originally Posted by alltheGHz View Post

I'm confused, do you want to cut a bunch of little 1mm discs or a bunch of 1mm holes? I'm not sure how you would do discs, but with holes dont spend a ton on some tool, just get a 1mm drill bit and call it good.

I am also confused as I did mention, perhaps not to well, that I am cutting the disks from 1mm plastic the disks need to be between 30-35mm in diameter with a 13mm hole in the centre. I am in effect making a washer(s) to cover the existing 19mm hole in my Parvum case to allow me to fit the missile switch which is only 12.5mm in diameter.
Quote:
Originally Posted by Lady Fitzgerald View Post

If your tolerances aren't too tight, use a drill to make the small hole. Sandwich the plastic between two thin pieces of wood to cut down on burring. Then use a leather hole punch to cut out the disk itself.

Since you are doing so few, you may be able to cut the disk out around the drilled holes using shears and a file to clean it up.

These two washers are already pretty close to the size you want:

http://www.mcmaster.com/#90295a494/=114pcg0

http://www.mcmaster.com/#90295a494/=114pcg0

I am in the UK and so far I have been unable to find washers to suit.
My hands are not steady enough for cutting out myself hence the need of a tool.
30-35mm leather punch?
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