Maya Ellison
When it comes to machining, plastic has its advantages over traditional materials like metal. Plastic allows for higher feed rates and creates less wear and tear on machines and cutting bits. The best plastic for machining will depend on the desired outcome and the specific requirements of the project. Some plastics are easier to machine, while others offer unique properties like transparency or impact resistance. For example, ABS is a versatile, cost-effective, and simple material to machine, but it has poor abrasion and chemical resistance. Polycarbonate is durable and transparent, but it is prone to scratches. Delrin (Polyoxymethylene, POM) is a high-strength plastic with superior resistance to wear, weather, and chemicals, making it ideal for CNC machining. Nylon is another strong and durable option with high chemical and heat resistance. Ultimately, the choice of plastic depends on the specific needs of the project, balancing functionality, appearance, and durability.
| Characteristics | Values |
|---|---|
| Ease of machining | Delrin/Acetal, PEEK, PVC, Polycarbonate, ABS, Nylon, Polypropylene, Polytetrafluoroethylene (PTFE), Polyethylene, Acrylic |
| Impact strength | ABS, Nylon, Polycarbonate |
| Toughness | ABS, Nylon, Polycarbonate |
| Electrical resistance | ABS, Nylon |
| Chemical resistance | PEEK, Nylon, Polypropylene, Polytetrafluoroethylene (PTFE), Polyethylene |
| Wear resistance | PEEK, Delrin/Acetal, Nylon, Polypropylene, Polytetrafluoroethylene (PTFE), Polyethylene |
| Temperature resistance | PEEK |
| Transparency | Polycarbonate, Acrylic |
| Cost-effectiveness | ABS, Nylon, Polypropylene, Polyethylene |
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What You'll Learn
ABS plastic is versatile, strong, and cost-effective
ABS plastic, or Acrylonitrile Butadiene Styrene, is a versatile, strong, and cost-effective plastic option with a wide range of applications. Its versatility stems from its ability to be easily moulded, sanded, and shaped into various forms, making it suitable for different manufacturing processes and end products.
ABS plastic is known for its high impact strength and toughness, thanks to its acrylonitrile and polybutadiene rubber components. This makes it ideal for durable consumer products that need to withstand regular use, transport, and accidental drops or bumps. ABS is commonly used in the automotive industry for interior and exterior components, such as dashboards, bumpers, door panels, and trim. It is also used in electronics, household appliances, and consumer goods due to its ability to resist impacts and its electrical insulation properties.
The versatility of ABS plastic also extends to its finish. It can be readily painted, glued, or welded together, and its glossy surface finish is compatible with a wide range of paints and glues. This makes it a popular choice for computer keyboard keys, LEGO bricks, and other products that require a smooth and aesthetically pleasing surface.
In terms of strength, ABS offers high tensile strength and is very resistant to physical impacts and chemical corrosion. This allows the finished plastic to withstand heavy use and adverse environmental conditions. However, it is important to note that ABS has a low melting point, making it unsuitable for high-temperature applications. Additionally, ABS has poor solvent and fatigue resistance and is susceptible to UV exposure and weathering unless adequately protected.
Lastly, ABS plastic is cost-effective to produce due to its relatively low-cost raw materials and efficient manufacturing processes. Its recyclability further contributes to its cost-effectiveness, as recycled ABS is widely available with properties similar to virgin resin. ABS's lightweight nature also improves fuel economy in vehicles and transportation, reducing overall costs.
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Delrin/Acetal is stiff and strong, but pricy
Delrin, also known as Acetal, is a stiff and strong plastic that is widely regarded as one of the best options for machining. It is a high-strength thermoplastic with exceptional mechanical properties and temperature resistance compared to other common plastics. Delrin's stiffness and rigidity make it ideal for tight tolerance machining, and it holds tolerances well without warping excessively. Its excellent machinability means it can be worked on with standard machines and cutters, and its high impact resistance and low friction characteristics make it perfect for gears, door system components, and bushings.
However, Delrin/Acetal is also known for being one of the more expensive plastics on the market. To mitigate the costs, it is recommended to design parts to standard sizes, as acetal is typically supplied in sheets of standard thicknesses or extruded forms. Custom stock orders can increase costs and lead time. Additionally, minimum wall thicknesses may be difficult to reproduce and can drive up pricing.
While Delrin/Acetal is pricier than some other plastics, its superior mechanical properties and ease of machining make it a popular choice for a variety of applications. It is often used in high-precision mechanical components such as gears and bearings, and its dimensional stability ensures that the end product meets the required specifications.
In conclusion, Delrin/Acetal is a stiff, strong, and highly machinable plastic that is well-suited for tight tolerance machining and high-precision parts. While it carries a higher price tag, its versatility, durability, and mechanical properties make it a preferred option for many industrial applications.
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Polycarbonate is durable, but prone to scratches
Polycarbonate is a popular plastic for machining, offering a range of benefits. It is known for its durability, impact strength, and versatility. However, one of its drawbacks is that it is prone to scratches due to its molecular structure.
Polycarbonate's durability is a significant advantage, making it suitable for various applications, including optical disks, safety glasses, light pipes, CDs, DVDs, mobile phones, and even bulletproof glass. It is also used in architectural glazing and machine guards, showcasing its versatility and impact strength.
The scratch resistance of polycarbonate is a concern, and it is important to understand the role of molecular bonds and coating technology in improving scratch resistance. Innovations in manufacturing have led to stronger bonds between polymer chains, resulting in a more resilient surface that can prevent or reduce the visibility of scratches.
Coatings, such as silica or other hard materials, provide an additional barrier. These coatings chemically bond with the polycarbonate, creating a long-lasting protective shield. Nanoparticles in these coatings further enhance scratch resistance by creating microscopic roughness, making it harder for larger scratches to form.
Scratch-resistant polycarbonate products, such as TUFFAK® AR polycarbonate, offer enhanced scratch and abrasion resistance. They provide glass-like surface hardness and impact strength while maintaining the desirable qualities of standard polycarbonate. These products are virtually unbreakable and meet various regulatory and safety standards, making them suitable for a wide range of applications.
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Nylon is strong, durable, and resistant to abrasion
Nylon, a polyamide, is a high-performance thermoplastic known for its strength, durability, and resistance to abrasion. It is a popular choice for machining due to its ability to maintain its mechanical properties at elevated temperatures and its resistance to chemicals. Nylon is strong and stiff yet lightweight, making it an excellent alternative to metal in various applications.
Nylon's strength and rigidity are attributed to its highly ordered crystalline structure, which lends the polymer its durability and resistance to deformation. This makes it suitable for applications where strong and durable parts are required, such as gears, industrial bearings, nozzles, sheaves, and wear pads.
Nylon is available in different grades, the most common being Nylon 6 and Nylon 6/6, which offer slightly different attributes. Nylon 6 is often used in textile and industrial applications, while Nylon 6/6 provides higher chemical and heat resistance with the rigidity needed to retain its shape. Nylon 6/6 is also more resistant to moisture absorption, which can cause swelling and affect dimensional accuracy.
Nylon exhibits good resistance to chemicals, alkalis, dilute acids, and oxidizing agents. It also has excellent wear resistance, a high modulus of elasticity, and high resistance to impact, abrasion, and vibration. These properties make nylon ideal for reducing noise and inducing less wear on mating parts compared to metal alternatives.
While nylon offers numerous advantages, it can be challenging to machine due to the nature of the chips/swarf produced during manufacturing. However, with the proper tools and techniques, such as high-speed steel cutting tools and optimal cutting speeds, nylon can be machined effectively.
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PEEK is a high-performance thermoplastic with high heat resistance
PEEK (polyether ether ketone) is a high-performance thermoplastic with exceptional mechanical and chemical resistance. It is a popular choice for critical applications in the aerospace, medical, and automotive industries, where its high-temperature performance and durability are essential.
One of PEEK's standout features is its ability to retain its properties even at high temperatures. With a melting point of approximately 343°C, it can operate continuously at temperatures up to 250°C without any loss in physical properties. This makes it ideal for use in hot water, steam, or other high-temperature environments. Its high-temperature performance is a significant advantage in demanding applications where failure is not an option.
PEEK is also known for its excellent chemical resistance. It offers resistance to corrosive chemicals similar to that of nickel steel and can maintain its non-corrosive properties even when in contact with most metals at high temperatures. Only concentrated sulphuric acid can dissolve PEEK under normal conditions. Additionally, PEEK demonstrates high electrical performance, even at elevated temperatures and frequencies, making it suitable for high-performance wire insulation.
The versatility of PEEK is another key advantage. It can be machined into various custom designs, from lightweight aircraft components to medical implants and custom medical devices. This adaptability, coupled with its high impact strength, wear resistance, and dimensional stability, makes it a preferred material in complex industries.
However, machining PEEK presents some challenges. Due to its low heat dissipation, it requires cooling during machining to prevent deformation or breakage. Additionally, its lower elongation compared to other plastics means that deep hole drilling can cause cracks. Special handling techniques, such as annealing, are also necessary to minimise internal stress and heat-related cracks.
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Frequently asked questions
The best plastic for CNC machining depends on the specific requirements of your project. Some plastics that are commonly used in CNC machining include ABS, polycarbonate, nylon, PVC, Delrin (POM), and PEEK. These materials are chosen for their ease of manipulation, cost-effectiveness, and ability to meet stringent technical requirements.
Plastics generally allow for higher feed rates and create less wear and tear on machines and cutting bits. They are also lighter weight, which contributes to lower lifetime freight costs. Additionally, plastics offer superior impact strength, toughness, corrosion resistance, and resistance to electrical and environmental stresses.
Harder plastics such as acrylic or ABS are recommended for CNC engraving as they provide more consistent and precise engraving results.
Acetal, PEEK, and PVC are the best materials for milling as they have superior machining characteristics and offer good dimensional stability.
