CNC Plastic
What is CNC Plastic
Plastic CNC machining is a process that uses computer-aided design (CAD) and computer-aided manufacturing (CAM) to create 3D objects from plastic material. This plastic machining process can be used for a variety of purposes, including prototyping, product development, and manufacturing.
Advantages of CNC Plastic
Precision and Accuracy
One of the most significant advantages of plastic CNC machining is its precision. CNC machines can produce parts with tight tolerances and fine details that might be difficult or impossible to achieve with manual machining or other manufacturing processes.
Versatility in Design
CNC machining allows for the creation of complex shapes and intricate designs that are often required in modern plastic components. This versatility gives designers and engineers the freedom to create parts without the limitations of other manufacturing methods.
High-Quality Surface Finish
CNC machines can achieve excellent surface finishes on plastic parts, which is particularly important for visible components or those that require a smooth surface for functional reasons.
Speed and Efficiency
With CNC machining, once the initial setup is complete, parts can be produced relatively quickly. This efficiency is especially beneficial for medium to high-volume production runs.
Consistency
CNC machining provides consistency across parts, which is crucial for maintaining quality in large production runs. Each part will match the original design specifications precisely, ensuring uniformity in the final product.
Why Choose US
Our Factory
Our workshop occupies over 10,000sqm in a modern manufacturing facility, equipped with advanced machinery that offers the comprehensive manufacturing servince for sheet metal parts, machined parts, stamped parts and cast parts. and we are offering assembly service to our customers as per request in our own workshop.
Our Projects
We are committed to help clients realize the concepts and designs with support of our engineering and manufacturing advantages that includes projects made of processes as:
--Sheet metal fabrication
--CNC machining
--Casting
--Stamping & Forming Assembly
Our Certificate
Starway MFG is an ISO9001:2015 certified manufacturer, and also a 5-Star Premium supplier on Alibaba.com, serving global customers from many different industries, like Machinery, Building, Vehichle, Telecommunications ect.
Manufacturing Processes
For sheet metal parts, there are manufacturing steps inhouse like laser cutting, CNC bending, welding, grinding, PEM insertion ect
For the Machined parts, there are manufacturing steps inhouse like CNC milling, CNC turing, Grinding, Drilling and EDM wire cutting.
Our stamping machines range from 200-400 tons that allows our to do stage stamping and progressive stamping, tooling designed and built in house.
For high quantity aluminum parts, we are providing die casting service.
CNC Using Different Types of Plastics
A variety of different types of plastic materials can be used in CNC machining, depending on the application.
Nylon
When it comes to CNC plastic machining, nylon is a popular choice. Nylon is strong and durable, yet lightweight and easy to work with.
It also has a high melting point, making it ideal for use in high temperature applications. In addition, nylon is resistant to abrasion and chemicals, so it won't break down easily over time.
As a result, parts made from nylon are often more reliable and longer-lasting than those made from other materials. Nylon is also an excellent electrical insulator, making it ideal for use in electronic components.
PTFE
PTFE, or polytetrafluoroethylene, is a type of plastic that is known for being strong and durable. It is often used in applications where high temperatures are a concern, as it has a high melting point.
PTFE is also very resistant to chemical attack, making it a popular choice for use in chemical processing plants.
In addition, PTFE is non-stick, making it an ideal material for use in cookware and other applications where sticking and build-up are a concern.
When it comes to plastic CNC machining, PTFE is often used to create parts that will be exposed to high temperatures or corrosive chemicals. The non-stick properties of PTFE make it ideal for use in applications where lubrication is not possible or desirable.
PTFE is a versatile material that can be used in a wide variety of applications that require strength, durability, and resistance to high temperatures or corrosive chemicals.
Acetal
Acetal is a strong, lightweight plastic that is often used in CNC machining. It is easy to machine and has a low coefficient of friction, making it ideal for applications where high precision and smooth operation are required.
Acetal has excellent wear resistance and chemical resistance, making it a good choice for parts that will be exposed to harsh conditions.
It can also be easily joined using adhesive or welding, which makes it possible to create complex shapes and designs.
PET
Polyethylene terephthalate, or PET, is a type of plastic that is widely used in food and beverage packaging as well as in the manufacturing of medical devices and electronics.
PET is an ideal material for CNC machining due to its high strength and stiffness, as well as its resistance to impact and wear.
It can be easily machined to very tight tolerances, making it an ideal choice for applications where precision is critical.
While PET is not the cheapest option for CNC machining, its superior properties make it an excellent choice for many applications.
PEEK
Polyetheretherketone, or PEEK, is a semi-crystalline thermoplastic that offers a unique combination of properties, including excellent mechanical and chemical resistance.
It is strong and stiff, with a high melting point and is resistant to heat, chemicals, and wear. For these reasons, PEEK is often used in aerospace and medical applications.
PEEK is well suited to plastic CNC machining and can be machined using CNC technology to create precise parts with very minimal variation as it has a low coefficient of friction and high wear resistance.
It can also be machined at high speeds and does not produce harmful fumes during processing.
When machining PEEK, it is important to use high speed tools and coolant, as the material can produce a lot of heat when cut. In addition, machinists must take care to avoid chips and burrs, as these can cause the material to degrade over time.
7 Tips for Cnc Machining Plastic
Know your material
Acrylic is more shock resistant and more resilient than glass.
It is important to note that cast and extruded acrylic will cut very differently due to their varying properties.
We recommend working with cast acrylic over extruded as cast acrylic will result in a cleaner finish when machined on a CNC. It's also even more transparent than glass. Extruded acrylic is more brittle and will crack easier making it harder to work with.
Choose the right bit
A good machining strategy for plastic is to cut using a conventional direction. When working on any project, you want to use the right tool for the right job. The same is true when working with plastic. A best CNC practice is to use a spiral up cut with a single flute.
Securing your material
It is very important that you are able to secure your material so that it's as flush with the bed of the CNC as possible. When running your CNC, holding down your material so that there is no flex in the acrylic will save you headaches down the road.
If you have flex in your material, you will have excess vibration which will cause your cuts to be jagged and rough. It may also lead to cracks in your acrylic. This is especially true when working with even thinner material as it will be lifted by the bit during cutting and cause breakage.
Using double sided tape, adhesive spray, or vacuum hold down can help alleviate flexing of your material during cuts. You'll need to be extra cautious when cutting very fine/thin plastics. Double sided tape is a cost friendly method and has proven to be very reliable. If your CNC has aluminum T-slots like the i2R does, Hold down clamps are a simple and effective way for securing your material.
Know your Feeds and Speeds
When you CNC acrylic you must find the perfect balance in speed. Cutting too fast will result in too much friction and you'll risk melting the plastic and wearing out your bit too. Cutting too fast will result in too much friction and you'll risk melting the plastic and wearing out your bit too.
Know Depth of Cut
The general rule of thumb when figuring out your depth of cut is to use half the diameter of your tool.
For this acrylic project though, .0535" depth of cut worked well.
Set Your Tabs
If you're using hold down clamps, you'll definitely want to make use of tabs to keep from having your material fly out. You don't want to make your tabs too thick or else you'll have to sand them and it will leave a rough edge. The goal here is get the tabs just right and that they aren't too thin that your material flies loose. For the thickness of this project, a length of .1" and .03" worked well.
Listen to your cut
When ever machining on your CNC, always listen to the sound the spindle makes during cutting. The noise can tell you a lot about how your spindle is performing. The louder and more high pitch the sound, the more aggressive your spindle is working. The more aggressive the cut, the rougher your finish will turn out.
If the sound is too loud, slow down the cut by lowering your feed rate. In UCCNC, you can simply slow your feed rate while your CNC is running by clicking the (-) button next to the F-SET.
You can also slow down the spindle RPM in your CNC the same way by clicking the (-) button next to your S-SET. The max RPM on the i2R CNC air cooled spindle is 24,000 RPM.
How are Plastics Machined
Plastic machining involves several processes depending on the material and the product to make. Of the many processes used in popular rapid prototyping services, below are the three most popular plastic machining processes:
CNC Turning
CNC turning involves spinning the plastic polymer on a CNC lathe while a fixed CNC tool removes part of it to create the needed shape. The process is ideal for working with many shapes, although the most common workpiece shape is cylindrical. Choosing whether CNC turning is the right process requires you or the prototyping service to understand several factors, such as the desired productivity, outer diameter of the plastic polymer, etc.
CNC Milling
CNC plastic milling is the opposite of CNC turning, as the tools rotate while the material is fixed. Like CNC turning, it has high precision and accuracy and a uniform production rate due to the corresponding cutting speed of the tools. CNC milling is also suitable for working with flat and irregular shapes. The process involves using a single-point cutting tool that works on many axes (the common one is the 3-axis). The number of axes supported determines the flexibility of the process and its suitability in making complex components.
CNC Drilling
CNC Drilling involves boring a hole in a material using cutting tools in the form of drills. Holes of different sections are created in the material depending on the kind and shape of the drill. CNC machines used in drilling are multi-purpose since they also perform some milling and turning operations. They also come in different sizes and require an expert to ensure cost-effectiveness when making plastic components.
Applications for Plastic CNC Machining
Some of the most common applications for CNC machining include creating medical devices, automotive parts, aerospace components, and consumer electronics, though there are plenty of other applications in the manufacturing industry too.
Medical devices
When it comes to medical devices, precision is key.
CNC plastic machining allows for a high degree of accuracy and repeatability, which is essential for medical devices that must meet stringent safety standards.
In addition, it offers a number of other benefits, including a wide range of material options and the ability to produce complex shapes.
This process is quickly becoming the go to manufacturing method for medical device manufacturers.
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Automotive components
Designers and engineers are increasingly turning to CNC machines for the development of automotive components.
Plastic offers a number of advantages over traditional materials such as metal and wood.
It is lighter in weight, which can lead to reduced fuel consumption. It is also more resistant to corrosion and wear, making it ideal for parts that will be exposed to harsh conditions. And it can be moulded into complex shapes that would be difficult or impossible to create using other methods.
Plastic CNC milling is becoming an increasingly popular choice for the development of automotive components.
02
Aerospace components
Aerospace engineering is an advanced field that designs, tests, and builds aircraft, missiles, satellites, and spacecraft. The components of these machines must be able to withstand extreme conditions, such as high temperatures and pressures.
As a result, aerospace engineers often turn to CNC machines to create precision parts.
This process is well suited for creating complex shapes and fine details. And plastic is an ideal material for aerospace parts because it is strong yet lightweight and can withstand harsh chemicals and high temperatures.
For these reasons, CNC machined plastic parts are often used in aircraft brakes, fuel lines and nose cones.
03
Consumer electronics
CNC machines are a popular choice for consumer electronics. This is because they offer a number of benefits over other manufacturing methods, such as high precision and repeatability.
A CNC machine can also be used to create complex shapes that would be difficult or impossible to create using other methods.
Because of this, plastic CNC machining is often used for parts such as housing enclosures, LCD screens, and keypads.
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Tips for Machining CNC Plastic Parts
Part Setup
When you set up your CNC plastic blocks, be sure to remember. Plastic isn't metal. You can easily leave a large mark on the surface if you clamp the blank with too much force. Actually, if you apply too much force, the part will probably just crack.
Cutting Tools
Choosing the best cutting tools for plastic parts is a complex job. The reason for that is that plastic as well as composite materials have a very variable composition. Some plastics are strengthened with hard carbide particles or have some additives that enhance flexibility, thermal resistance, or some other parameter. All of that changes the way a plastic reacts to machining. So, depending on the characteristics of the different plastics, you should select the right cut tool for the machined plastic part.
Cutting Process
Let's look at the choice for plastic cutting processes by using the example of the CNC Milling Plastic case. The main issue that you have to look out for is excessive friction and plastic deformation of the part. To avoid these issues, always keep the cutters sharp in the cutting process. In cases, when the material you use isn't rigid enough, freeze it. However, You should be careful because plastic becomes hard and brittle under low temperatures.
Cutting Parameters
In order to prevent the chip from melting into the CNC plastic part, you'll need to keep that tool moving and prevent it from staying in one place for too long. Remove the chip as fast as you can. So, the feeds for plastic processing must be big, aggressive even. And with bigger feed rate parameters, the spindle speeds must be fast as well. The approximate estimation is about 3 times as fast as aluminum feeds and a corresponding cutting speed.
CNC Machining Surface Finishes for Plastic Parts
The company conducted a competitive advantage analysis to identify its strengths and weaknesses compared to its rivals.
As-machined
Parts fresh off the line with no added finish have improved uniformity and precise dimensions. A technician can CNC machine any plastic with an as-machined finish. However, this technique leaves minor visible tool marks. Softer plastics may be vulnerable without a protective coating.
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Bead blasting
A pressurized air gun blasts plastic parts with glass beads for a smooth matte or satin finish. This method offers pleasing aesthetics but only works for plastics with enough impact resistance.
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Wet sanding
Moistened fine-grit silicon carbide sandpaper smooths plastic to prepare for paint or polish. Be sure to apply a plastic-safe polish.
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Fire polishing
An open flame partially melts the plastic to smooth the surface for a polished look. This technique only applies to plastics that can tolerate the heat, never to those that melt easily or become toxic when heated, like polypropylene or PVC.
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Vapor polishing
A chemical vapor can polish dull plastic surfaces to a smooth sheen. It can enhance the properties of polycarbonate and acrylic but requires strict safety measures and is not ideal for all plastics.
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Material properties
Understanding the properties of the plastic material you are machining is essential. For example, some plastics are more prone to warping or melting, while others may be brittle and susceptible to cracking.
Design for manufacturability (dfm)
Designing parts with manufacturability in mind can simplify the machining process and reduce costs. This includes considering factors such as wall thickness, corner radii, and the inclusion of any undercuts or threads.
Tolerances and fit
Determining the appropriate tolerances for your parts is crucial. Tight tolerances can increase the cost and complexity of the machining process, so it's important to balance precision with practicality.
Post-processing
Post-processing steps, such as deburring, polishing, or painting, should be planned in advance as they can affect the overall lead time and cost of the parts.
FAQ
We're well-known as one of the leading CNC plastic manufacturers and suppliers in China. If you are going to wholesale customized CNC plastic at competitive price, welcome to get more information from our factory.
Plastic Milling, Plastic Machining Services, Plastic Turning