I used to make bunch of sub-woofer boxes out of acrylic and have to say, drilling is the hardest part for the screws. But there’s a better way to do this using laser cutters and whatnot, read on to find out.
It is a technique we call Interlocking T-Bolt Construction. It consists of a T-cutout in one piece of acrylic (or any 3 mm stock) and a receptacle in another piece. These pieces can then be bolted together making a very secure 90 degree joint. A deceptively simple technique that has unlimited possibilities.
All that is required is an idea, some drawing software, and access to a laser cutter.