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Plastic Machining
What is Plastic Machining?
Machining is a subtractive manufacturing process that removes material from a workpiece to create a desired shape, size, and surface finish. Plastic machining can produce simple to highly complex components with a high degree of precision and repeatability.
Modern machining is typically performed using computer numerical control (CNC), which precisely controls machine tools based on programmed instructions. CNC machining processes include milling, turning, drilling, Swiss machining, and micro machining.
How Does Plastic Machining Work?
Machining uses cutting tools to selectively remove material from a plastic workpiece. The appropriate machining process depends on factors such as part geometry, size, material, tolerances, and production requirements.
Milling uses rotating cutting tools to remove material from a stationary workpiece. It is commonly used to create flat surfaces, contours, pockets, slots, holes, and complex geometries.
Turning rotates the workpiece against a cutting tool and is commonly used to produce cylindrical components and features.
Drilling uses a rotating cutting tool to create round holes in a workpiece.
Swiss machining is a specialized form of CNC turning in which bar stock passes through a guide bushing that supports the workpiece close to the cutting tool. This reduces deflection and makes the process particularly well suited for small, slender, and complex precision parts. Swiss machines can combine turning with milling, drilling, and other operations to produce multiple features in a single setup.
Micro machining uses precision machining techniques to produce very small components or microscopic features. Specialized tooling and process control are used to achieve the dimensional accuracy and surface quality required at extremely small scales.
Other specialized plastic machining methods include boring, broaching, reaming, threading, and grinding.
Advantages of Plastic Machining
Plastic machining provides excellent precision and design flexibility across a wide range of part sizes, geometries, materials, and production quantities.
Advantages include:
High dimensional accuracy
Excellent repeatability
Complex geometries and fine features
Tight tolerances
High-quality surface finishes
Broad material compatibility
Ability to produce very small and intricate components
Suitable for prototypes through production quantities
Plastic Machining Materials
A wide range of thermoplastics and engineering plastics can be machined, including:
ABS
Polycarbonate (PC)
Polypropylene (PP)
Polyethylene (PE, HDPE, LDPE)
PET
Nylon
Acetal / Delrin
PPSU / Radel
PPS / Ryton
PVC / CPVC
Acrylic
PTFE / Teflon
Torlon
PEI / Ultem
PEEK
Material selection depends on the mechanical, environmental, thermal, electrical, weight, and cost requirements of the application. Machinability also varies by material and can influence tooling, production speed, achievable finish, and manufacturing cost.
Plastic Machining Applications
Plastic machining is used to manufacture precision components across a wide range of industries.
Aerospace: Structural and interior components, housings, fittings, insulators, sensors, connectors, and precision mechanical components.
Construction: Fasteners, hand tools, accessories, window and door hardware, pipe and electrical fittings
Consumer: Containers, packaging, dog toys, electronic devices, household items, electronic device cases, appliances, furniture, toothbrushes, toys, sporting goods
Defense: Sight scope, EMI/RFI shielded devices, security equipment, firearms components, optical components for weaponry, combat gear and devices
Energy: Chemical sensor device, metering equipment, smart grid components, fluid handling equipment
Industrial: Housings, pumps, valves, gears, bushings, fittings, tooling, and automation components
Medical: Drug delivery devices, respiratory equipment and disposables, diagnostic test kits, device packaging, prosthetics, surgical and diagnostic equipment components, implants, device components, miniature components, fittings, insulators, and precision hardware
Technology: Housings, connectors, insulators, spacers, sensor components and miniature precision components
Transportation: Housings, bushings, fittings, fluid-handling components, electrical components, and other precision mechanical parts
