Ethan Clarke
Thread tapping in plastic is a process that involves creating threads on the inner sides of a hole. This is done with a device called a tap, which is a metal cylinder with threads at one end that is inserted into the drilled hole and twisted. While it is possible to tap threads in plastic by hand, using a tap wrench or a hand drill can make the process more efficient. Tapping threads in plastic requires careful consideration of the type of plastic, the size of the hole, and the appropriate tools to ensure a secure fit without causing damage.
| Characteristics | Values |
|---|---|
| First Step | Drill a hole in the plastic |
| Second Step | Create threads on the inner sides of the hole |
| Tool | A tap (a metal cylinder with threads at one end) |
| Tap Size | Should be the same diameter as the hole |
| Drill Bit | Metal drill bit |
| Tap Position | 90 degrees to the surface of the plastic |
| Tap Direction | Turn clockwise 1/4 turn, then counterclockwise to remove plastic shavings |
| Tap Alternatives | Screw itself, nut trap, pipe tap, homemade tap, bolt with a taper, threaded PVC bushing |
| Tap Coolant | Distilled water, liquid soap |
| Tap Material | Chrome-plated taps to prevent rust |
| Tap Type | Bottoming tap for holes smaller than 1/4"; tap wrench for holes larger than 1/4" |
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What You'll Learn
Drilling the hole
When drilling the hole, it is important to ensure that the plastic is securely clamped or held in place to prevent movement. The drill bit should be inserted perpendicular to the surface of the plastic, at a 90-degree angle. This will ensure that the hole is drilled straight and that the threads will be properly aligned.
It is also important to consider the type of plastic you are working with. Some plastics, such as Perspex, are softer than others and may require different techniques or tools to prevent cracking or other damage. Additionally, when drilling into plastic, it is important to use a slow speed to avoid melting the plastic or causing other damage.
For larger holes, a drill press or similar machine may be necessary to ensure accuracy and stability. When drilling by hand, it is important to apply even pressure and maintain a steady pace to achieve a clean and accurate hole.
Once the hole has been drilled, it is important to remove any plastic shavings or debris before proceeding to the tapping process. This can be done by blowing compressed air into the hole or using a small brush to clear away any remaining material.
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Choosing the right tap
Tap Type
The type of tap you choose depends on the specific application and the desired results. Some common tap types include:
- Straight Flute Tap: This tap type has straight flutes and is typically used for creating straight internal threads.
- Spiral Point Tap: Spiral point taps are designed for use with through holes or blind holes with ample clearance beneath the threads. They create internal threads with a spiral point, which helps evacuate chips and reduce friction.
- Spiral Flute Tap: Also known as gunmaker's taps, these taps have a spiral flute design, making them suitable for non-hard materials like plastic.
- Form Tap: Form taps, also referred to as roll form taps, create threads by deforming the material instead of removing it. This method is faster and reduces friction and heat buildup, making it suitable for soft plastics.
- Combined Drill Tap: This tap type combines drilling and threading operations in a single tool. It has a drilling bit at the endpoint and thread-cutting flutes, allowing for tighter specifications and faster production.
Thread Form and Material
Consider the type of thread form and material you want to work with. Different thread forms, such as unified thread forms (UN) and their variants (UNC, UNEF, etc.), require specific taps. Additionally, the workpiece material type will determine the tap material. For example, carbide taps are suitable for stainless steel and titanium, while high-speed steel taps may struggle with these materials.
Hole Type
The type of hole you want to thread, whether it's a blind hole or a through hole, will influence your choice of tap. Spiral point taps, for instance, are suitable for through holes or blind holes with sufficient clearance.
Tap Size and Specifications
Refer to thread tap sizing charts and tolerance tables to ensure you select the correct tap size and achieve the desired precision. Match the tap's specifications, including drill diameter, tap diameter, depth, thread spacing, and material compatibility, to your specific requirements.
Experience and Recommendations
Consider your level of experience and seek recommendations from experienced individuals or online communities. For instance, some users have shared their positive experiences with form taps for soft plastics, while others suggest using a larger tap to compensate for plastic resizing after cutting.
By carefully considering these factors, you can choose the right tap for tapping threads in plastic and ensure a successful and efficient threading process.
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Using a tap wrench
Tapping threads in plastic requires first drilling a hole and then creating threads on the inner sides of the hole. This can be done by hand with a standard tap wrench. A tap wrench is a handle with a square or hexagonal opening used to turn and guide the tap into the workpiece.
To use a tap wrench, start by drilling a hole that is slightly smaller than the diameter of the threading tap. This will ensure a tight fit and clean threads. Align the tap with the mouth of the hole, ensuring that it is at a 90-degree angle to the surface of the plastic. Apply some cutting fluid if needed to reduce friction and heat.
Using the tap wrench, turn the tap clockwise while applying gentle pressure downwards. Take your time and ensure that the tap cuts smoothly into the material. Occasionally, reverse the tap by turning it anti-clockwise to help clear any chips or debris. Continue turning the tap in this manner, alternating between clockwise and anti-clockwise directions, until you achieve the desired thread depth.
Once the tap has cut through the entire thickness of the workpiece, remove it by turning it anti-clockwise and wipe away any plastic shavings. It is important to note that the tap must be very sharp to effectively cut through the plastic. Additionally, consider using distilled water as a coolant when tapping threads in plastic.
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Using a hand drill
Tapping threads in plastic using a hand drill requires some preparation and the right tools. First, you need to decide on the type of tap you want to use. A bottoming tap is recommended for plastic as it makes a cleaner cut and produces less friction and heat than plug or taper taps. You can also use a standard tap wrench, but this is more suitable for sizes larger than 1/4".
Next, you need to choose the right drill bit size for your project. It is important to get the right size of tapping drill for successful thread tapping. Spiral tapping bits that fit into a drill/driver are a good option, as they allow you to drill, thread, and counter-sink in one operation.
When tapping threads in plastic, it is important to use a lubricant to ensure a smoother operation and extend the life of the tap. You can use WD40, oil, or even Vaseline. Additionally, using a coolant during the tapping process can help prevent the plastic from melting due to friction and heat. Distilled water is a good option for a coolant, as it leaves no residue after being blown clean with compressed air.
Now you are ready to start drilling. It is recommended to use a low-voltage cordless drill with the softest clutch setting to avoid applying too much pressure and risking splitting the plastic. You can adjust the clutch as needed, but be careful not to apply too much torque, especially when drilling through thin plastic.
Finally, it is important to note that tapped holes in plastic are not load-bearing and can be fragile. If you need to hold a bolt that carries a load, consider using a nut trap or increasing the number of shells used to strengthen the threads. You can also use a technique called Orbital tapping to achieve perfect threads in moulded plastic parts.
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Safety considerations
Firstly, it is crucial to select the appropriate tap for the specific plastic material being used. Different plastics have unique characteristics, and using the wrong tap can result in poor thread quality or damage to the plastic. It is also important to match the tap size to the hole size. Using a tap that is too large or too small can lead to inadequate thread formation or plastic deformation.
Secondly, cooling the plastic is essential to prevent overheating and potential melting. This can be achieved by using coolants during the tapping process or, in some cases, distilled water as a coolant. Overheating can also be caused by using an electric driver at high speeds, so it is recommended to use a driver with a real clutch to maintain control and prevent damage to the plastic.
Additionally, plastic chips and shavings can accumulate during the tapping process, potentially causing obstructions or affecting the thread quality. It is important to regularly clear these away and ensure they do not interfere with the tap or the newly formed threads. This can be achieved by periodically turning the tap handle counterclockwise to remove plastic shavings.
Furthermore, safety precautions should be taken to protect the user from any sharp edges or debris created during the tapping process. Eye protection is essential to shield against plastic chips and dust, and gloves can provide a secure grip on the tools while safeguarding the hands from sharp edges.
Lastly, it is important to be cautious when tapping threads in thin plastic sections or areas with complex geometries. These areas may be more prone to cracking or deformation, so extra care and precision are necessary to avoid damaging the plastic component. In some cases, it may be advisable to consult an expert or seek technical assistance to ensure the process is carried out safely and effectively.
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Frequently asked questions
The process involves first drilling a hole in the plastic and then creating threads on the inner sides of the hole using a device called a tap.
A tap is a metal cylinder with threads at one end that is inserted into the drilled hole and twisted.
There are bottoming taps, plug taps, and taper taps. Bottoming taps are recommended for plastic as they produce less friction and heat.
The tap should be the same diameter as the hole. For example, if you are drilling a 1/2-inch hole, use a 1/2-inch tap.
Use a metal drill bit and ensure the tap is at a 90-degree angle to the surface of the plastic. Turn the tap handle slowly clockwise, then counterclockwise to remove plastic shavings. For cooling, you can use distilled water or compressed air.
