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PLASTIC MILLING

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Plastic Milling

Plastic milling is a routing process that uses a milling cutter to remove polycarbonate sheets or acrylic sheets from the surface of a product.

Compared to drilling, where the tool is much more advanced along its rotation axis, the cutter in milling is usually moved perpendicular to its axis, so that cutting occurs on the circumference of the cutter.

Milling is very popular in plastic machining, especially when the tooling cost is high, for small quantities. There are many plastic parts that can be made by milling. Polycarbonate milling and acrylic milling are normally combined together with other processing, such as CNC routing, vapor polishing, and etc. 

 

  • Polycarbonate parts
  • Polycarbonate medical device components
  • Polycarbonate manifolds

The Difference Between CNC Router and CNC Milling

CNC router can cut complex shapes.

It’s used for rapid prototyping and engraving.

A router is especially useful for large pieces like signs or plates.

CNC mills are suited for a broader range of materials, including harder metals, because of their heavy-duty design and precision capabilities.

The workpiece design and path of the cutting tools are pre-programmed using CAD and CAM software.

CNC routers are limited in their Z-axis range and are not ideal for deep cutting, whereas mills can handle precision micro machining.

CNC router

Materials:

ABS, PMMA(Acrylic), polycarbonate, HDPE, PVC and PS are all suitable for CNC Plastic Milling Machining.

Machining Speed:

A router operates much more quickly when machining speed is considered.

Component Type:

A CNC mill is preferred for producing high-precision parts, such as components for airplanes, equipment parts.
If you need parts for highly sensitive applications, such as military, medical and marine industries, a CNC mill provides much more accurate cuts than CNC routers.

Cutting Area:

a CNC mill can offer a deeper Z-axis for deeper cuts in the work.
If your source material is very large or wide, such as large blocks of polycarbonate or acrylic panels, you may have to opt for a router, which has a large cutting area.

Advantages of Plastic Milling

Mold-free:

No need for expensive injection molding cost. 

Quick production of prototypes for testing and design validation. 

Tighter Tolerances and Part Intricacy:

High-precision measurements compared to injection molding and 3D printing processes. 

Making Large Plastic Parts:

3D printing large plastic parts are not feasible because it takes longtime, and high costs. But CNC Mill only takes a few minutes. 

Wide Range of Materials:

Excellent structural properties, such us:

  1. Electrical Insulation: Suitable for applications requiring non-conductive materials.
  2. Low weight but high strength performance.
  3. Clear and aesthetically 
  4. High precision and strong
  5. Excellent  thermal and chemical resistance
  6. Impact resistant and easy to machine
CNC milling

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The versatility and cost effectiveness of the plastic thermoforming process make it an ideal choice for a wide array of industry applications. Plastic thermoformed parts are commonly used to replace fabricated sheet metal components and also offer some unique advantages over parts constructed with FRP manufacturing processes. Whether your project is a new design or a process conversion from an existing one, thermoforming your components with Excelite can be an ideal solution for countless applications and industries.

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Plastic Milling Parts

Milling is used widely when tooling fee is high and quantity is small. We can proceed on various types of materials. Food and Beverage Industry parts, medical devices.

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Semiconductor Parts

Precision of plastic CNC machining.

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Automotive and Aerospace Parts

Aerospace and automotive industries require the strict regulations and requirements. 

FAQ

Most frequent questions and answers

The best plastics for milling include:

  1. Acrylic: Clear, easy to machine, and visually appealing.
  2. Nylon: Strong and wear-resistant, great for durable parts.
  3. Delrin: High strength and precision, ideal for detailed components.
  4. Polycarbonate: Tough and impact-resistant, suitable for various applications.
  5. HDPE: Lightweight and chemical-resistant, commonly used in containers.
  6. PETG: Strong and clear, good for transparent parts.
  7. PEEK: High-performance plastic for demanding environments, though harder to machine.

These plastics are chosen for their properties and suitability for different milling applications.

The cost of plastic CNC machining depends on many factors, including the material used and the expertise of the machining services provider or CNC milling machine shop.

Plastic CNC machining is a process of using computer numerical control (CNC) machines to shape and cut the plastic material into the desired shape. This technique is highly accurate, allowing for the production of complex designs with intricate detail or complex geometries.

Why Work With Us

With over 15 years of polycarbonate fabrication and machining experience, Excelite specializes in the fabrication of polycarbonate and acrylic sheet products, ensuring top-notch quality and precision. We are committed to providing the best manufacturing solutions tailored to your unique requirements. 

Whether you have a detailed drawing or just an idea, our team of professionals is ready to turn your vision into reality. Enjoy the benefits of our services, including:

In-house Design & Tooling

Exceptional Accuracy (+/- 0.005″ Tolerances)

Comprehensive OEM & ODM Services

ISO 9001:2008 Certification

Direct Manufacturer Advantage

We invite you to partner with us and experience a seamless, efficient, and quality-driven production process.

 
 
TAILORED POLYCARBONATE SOLUTION

Get a Quote Today

Looking to transform your vision into a tangible product? 

At Excelite Plastics, every project is unique.

sales@exceliteplas.com

+86 135 8555 4902 (China)

+61452 396 680 (Australia)

Block 1 RuiSu Building, 2 Kecheng Rd, Suzhou, China 215122

Australia Branch: 6 Stephen Road, Dandenong South 3175

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