More about Machined Plastics

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With the continuing development of plastics, plastic machining processes have become essential manufacturing operations. Machined plastics are found in an ever widening range of industries and products, and have helped expand their capabilities. For precision, close-tolerance and complex plastic parts, plastic machining is often a necessity.

Plastics can be machined with many of the same processes used for metals. Common plastic machining operations are CNC milling, turning and drilling; polishing; bonding and welding; and laser cutting. Typically, injection molded plastics do not require additional machining, while it is often necessary for blow molded and extruded plastics. The machining operations performed may be as simple as lathing or cutting, but can be far more complex. In fact, four- or five-axis machining processes are performed with increasing frequency on plastics. In large degree, this is due to the expanding use of plastics and to the increasingly complex needs of the industrial marketplace. The improvements and advances seen in electronics, computers and mechanical engineering (among other industries) have led to the need for more sophisticated and detailed parts, and elevated the demand for machined plastics.

Although standard high-speed steel (HSS) tools and carbide tools typically used on metals are suitable for plastic machining, specially designed tools enhance production rates and are generally more effective. For instance, tools specialized for plastic machining are better able to remove plastic chips in various drilling and cutting operations, while others (i.e., diamond tools) are particularly effective with filled polymers. Tool sharpness is essential to prevent issues caused by melted plastic, and a high cutting speed and low feed rate are norms in plastic machining operations.

Although most molding procedures are far less expensive solutions for many projects, especially long production runs, machined plastics continue to become a more economical answer. For high-precision, short run components, it is difficult to find a more effective manufacturing method. In many cases, machined plastics are the only or best option.