On 2010-07-01 12:43:46 -0400, "Joe AutoDrill" said:

I've got a customer trying to drill a 1-1/16" diameter hole through a
thin (1/16") piece of wood/plastic composite material.

Is the end result the hole, or the material removed from the hole?

What about a punch and die and an arbor press? Probably better with a
flexible plastic, but you remember those balsa airplanes you'd punch
from a sheeet?