How to cut small square hole in a plastic case

Hello everyone.

I have a Raspberry Pi and with a plastic case. What tools/options do I have that'll allow me to EASILY cut a square hole? Or any shape, really.

Any advice will help, thanks!

 

I do it like this: Drill round hole, cut-out round corners with x-acto knife, sand down all edges until everything looks perfect.
Ofc there might be a better way.

 

Can do it with some patience and a dremel tool, I'd start making the hole a tiny bit smaller than I needed and sanding out the edges for a snug fit. Need to take it slow because it is extremely easy to over cut depending on the bit you are using.

 

What kind of dremmel? What do you use it sand it down?

 

I've found that drilling a hole in the center then using a file to get the shape of the square works rather nicely. That's what I did when I installed the switch in my mega drive.

 

If you have the spare dosh or access to one, use a laser cutter.

 

Any rotary tool will do the job with the correct cutting disc; if you want to go name brand, Dremel is the way to go with all the accessories and attachments that are available - for future projects

I own corded and cordless Dremel tools.. depends on your needs and budget as far as what you want to get.

When using a rotary tool - use the slowest RPM setting when cutting plastics. At a high-speed, you can easily warp and burn plastic. If you need to use a higher RPMs... make those cuts quick.

When cutting a slot for my SD card on an Everdrive cart.. I've used a drill bit about the size/width of the opening on each end and used the cutting disc to cut the length of the SD slot opening perpendicular to each other. If you are cutting larger squares.. you can use the width of the cutting disc on all four sides. If its a rectangular opening and you have two short sides and cannot use the cutting disc on the short ends... use a small drill bit on the corners and then cut in-between with a cutting disc for the long sides and on the short ends score the plastic in-between the holes with a hobby knife... bend the plastic back and forth until it breaks and finish things off with hobby files - these are small files that work great for intricate work.

 

It depends on how small of a square hole you want. If it's big enough, then a cutting disc will work great. Otherwise, for smaller holes for things like switches, I would cut out a rough hole, then file it out the corners to what you want it to look like with a square profile file. Just be sure to take your time. It probably won't be perfect, but without some expensive tools, it's really all you can do.

 

Forgot to mention.. I use masking tape to mask-off my cutting lines. You can do this on the smallest of cut-outs.

Use whatever method you need to remove the plastic and finish by filing up to the tape line. Makes for nice straight lines and sharp corners.

It works as a nice template especially on uneven and curved surfaces.