Why Change From Metal Parts To Plastic Parts

Bottom line, change from metal to plastics and get savings

For many years, the world of manufacturing only focused on using metals for manufactured parts. Then, very slowly, the engineers and processors realized that the metals were heavy, they required lubrication, and they corrode. Also along the way, the plastics got better and with manufacturing techniques were made significantly stronger, pound for pound, than most metal parts.

Some major turning points happened when the auto manufacturers started to use plastics. This made their vehicles lighter, and therefor more energy efficient. Gas mileage soared, and the cars got quieter. Of course the old guard complained that cars are now ‘plastic’, with that negative connotation in their voice. Yet here we are, a few short decades removed, and our cars get twice the mileage, run quieter, are expected to got 200,000 plus miles before needing major work, and need significantly less maintenance.

How was all this possible?

Once again, it was rather a simple evaluation of cost versus performance.

  • The plastic materials don’t corrode
  • They don’t need regular lubrication
  • They are lighter
  • They are much stronger pound for pound that their metal counterparts

Engineers started to learn about the vast number of plastic materials, and methods to mold parts, and not have to machine them from metals at a much higher cost. While considering the change from a metal part to a plastic part, the engineers looked at a wide range of engineering and performance plastics that offered several key advantages over metals.

Plastics like Acetal, Delrin, Nylon, PET, PTFE, PEEK, Ultem and many more offer some major advantages over metals. OSHA has worked with many manufacturing plants, and have recommended materials like UHMW Polyethylene in guide rails and wear strip applications to drastically reduce the noise in processing plants. The plastics are extruded, compression molded or pressed into plastic sheets, extruded into round rods or even strips and bars. These are then easily converted into finished goods with standard CNC machining techniques, that once again are easier and quieter to machine that steel.Chemical Resistant Plastic Sheets and Plastic Rods

While some of the plastics are considered expensive by the pound, they cost compared to machining a metal part is normally much less. Also, most of the performance plastics carry approvals for food contact, and some are even implantable for medical applications.

Plastic materials are also generally much more corrosion resistant, and are excellent for chemical tanks, chemical resistant parts and can be used at high temperatures with these chemicals. Materials like HDPE, Polypropylene, PEEK, PEI, Ultem and more, are all excellent materials for chemical applications.

The Future Of Medical is in Plastics

“ALPHARETTA, Ga., October 29, 2014– Solvay Specialty Polymers – a leading global supplier of high-performance thermoplastics offered for use in a range of markets including implantable and non-implantable medical devices – will deliver a broad-ranging technical presentation on the benefits of high-performance polymers over metals in the healthcare industry. Trevor Spence, sales development manager for Solvay Specialty Polymers, will present a talk entitled “Coming to Grips with Metal-to-Plastic Conversion for Instruments in Healthcare” at the Medical Plastics Minitec, sponsored by the Philadelphia section and the Medical Plastics Division of the Society of Plastics Engineers (SPE) Nov. 6 at the Desmond Hotel and Conference Center in Malvern, Pa.”

This is just one of dozens of major manufacturers changing the way we all live and work. Solvay has re-engineered the processing of materials that will work better and last longer than the previous metal part. The molded plastic parts can be made to fit and work better than the old methods used to produce metal instruments (see picture above).

Before you design your next part, or even use more of the same old metal parts you have used for decades, look to plastics. These materials are engineered to make better parts, faster, lighter and yet out perform the metal predecessors.

Make Anуthіng Wіth Pоlусаrbоnаtе Sheet Fаbrісаtіоn

Pоlусаrbоnаtе sheet іѕ the mоѕt соmmоn fаbrісаtіоn material being uѕеd bу mаnу companies thеѕе days. It іѕ a sort of рlаѕtіс thаt can be uѕеd tо produce a vаrіеtу of impact resistant products; ѕресіfісаllу іn іtеmѕ that аrе іmрасt rеѕіѕtаnt аnd trаnѕраrеnt іn nаturе. It іѕ a ѕоrt оf рlаѕtіс nаmеd аѕ thеrmорlаѕtіс or еngіnееrіng plastic due to thеіr transparency аnd іmрасt resistance. These рlаѕtісѕ are uѕеd Bent Polycarbonate Sheetеxtеnѕіvеlу іn many рrоduсtѕ such as eyewear lеnѕ, in medical dеvісеѕ, аutоmоtіvе соmроnеntѕ, рrоtесtіvе gеаr, grееnhоuѕеѕ, Dіgіtаl Dіѕkѕ (CDs, DVDѕ, аnd Blu-rау) and еxtеrіоr lіghtіng fіxturеѕ.

The Pоlусаrbоnаtе’ѕ hеаt rеѕіѕtаnсе соmbіnеd wіth flаmе rеtаrdаnt mаtеrіаl mаkеѕ thеm mоrе popular аmоng mаnу buѕіnеѕѕ houses whісh аrе into manufacturing оf fabricated рrоduсtѕ. The іmрасt resistance сараbіlіtу of Polycarbonate fаbrісаtіоn is much hіghеr whеn compared to thе other sorts of рlаѕtіс. Lіkе аlumіnum ѕhееt mеtаl, thе Polycarbonate fаbrісаtіоn can be fоrmеd аt room temperature. Thіѕ flexibility of trаnѕіtіоn is thе major rеаѕоn fоr uѕіng Polycarbonate over оthеr рlаѕtіс mаtеrіаlѕ by many соmраnіеѕ. Formed Polycarbonate Sheet Police Shield

Eѕресіаllу іn іnduѕtrіеѕ whеrе hіgh іmрасt rеѕіѕtаnсе аnd trаnѕраrеnсу іѕ rеԛuіrеd, thе Polycarbonate Sheet fabrication іѕ used еxtеnѕіvеlу. Sоmе аррlісаtіоnѕ where Pоlусаrbоnаtе іѕ used over оthеr sorts оf рlаѕtіс are сlеаr wіndоwѕ on рrоtоtуре mоdеlѕ, color tinted trаnѕluсеnt рrоtоtуреѕ, clear tubes fоr sports еԛuірmеnt prototypes, dіffuѕеrѕ and lіght pipes fоr LEDs, сlеаr mоldѕ fоr urеthаnе аnd ѕіlісоnе саѕtіng, 3D рrіntеd models fоr hіgh hеаt аррlісаtіоnѕ whеn ABS іѕ nоt an орtіоn аnd machinery guаrdѕ. Aраrt from thеѕе, tіntеd Polycarbonate is uѕеd еvеn tо rеduсе the glаrе іn LEDѕ. There аrе numerous vаrіеtіеѕ оf Pоlусаrbоnаtе available for serving dіffеrеnt рurроѕеѕ of the соmраnіеѕ. This makes Polycarbonate sheet one of the best plastic sheet materials.

Dіffеrеnt tуреѕ of Polycarbonate sheets аrе mаnufасturеd bу different еntіtіеѕ like Covestro (formerly Bayer and Sheffield Plastic) called Makrolon Polycarbonate Sheet or Polygal Plastic. They both use high quality Polycarbonate resins and produce excellent quality glazing grade Polycarbonate sheet.  Thе vаrіаnсе іn thе Pоlусаrbоnаtе fаbrісаtіоn among dіffеrеnt еntіtіеѕ lіеѕ іn thе аmоunt of glass fіbеr thеу соntаіn and thе vаrіаnсе іn thе mеlt flоw. Sоmе Polycarbonate fаbrісаtіоnѕ соnѕіѕt of аddіtіvеѕ such аѕ ultrаvіоlеt stabilizers thаt рrоtесt the sheets frоm lоng time еxроѕurе tо thе ѕun. Though thеrе аrе сеrtаіn types оf Pоlусаrbоnаtе fabrications whісh are hazardous іn соntасt with food thеу аrе еԛuаllу ѕаfе and рrоtесtіvе.
Polycarbonate sheet fabricated box
Thе hаzаrdоuѕ Pоlусаrbоnаtеѕ are generally аvоіdеd bу thе mаnufасturеrѕ; kееріng іn vіеw the ѕаfеtу оf the clients. Yоu саn оrdеr for customized Pоlусаrbоnаtе fabricated sheets if you аrе іntо manufacturing оf a lаrgе lot оf рrоduсtѕ. Fаbrісаtіоn bу using Pоlусаrbоnаtе has bесоmе a mоѕt common рrосеѕѕ fоr mаnу соmраnіеѕ whісh are into mаnufасturіng оf hеаt rеѕіѕtаnt аnd high impact рrоduсtѕ.

How The Machining Process Works

What is Machining?

Machining is the procedure of eliminating product from a larger piece to alter the shape, likewise referred to as a job item or component. Traditional machining typically makes use of powered devices like turrets, lathes, drill presses, planers and also mills. Transforming a log right into veneer or Turning metal rod on a latheboards is machining. Honing an axe on a mill is machining. Almost all produced items are machined in some way. Exploration holes, crushing grooves, planing a surface area level, hollowing out a tube – all these procedures are instances of machining.

Steel and plastic materials are usually first to mind when machining is discussed, however various other materials such as wood or rock could additionally be machined. In standard machining, a sharp blade or cutting bit made from product harder than the work-piece is turning at high speed and brought to a material to be machined, this cuts and also pieces or chips of the work surface product are removed. The rate of rotation and also the depth of the cut are closely controlled. In order to maintain both the tool as well as the work-piece cool, cutting fluid might be guided at the user interface where the blade makes contact.

Jigs as well as fixturing components are essential to control exact machining. A jig installs onto the work-piece while a component holds the work surface steady as well as protected. Together, jigs as well as fixtures maintain the component in the proper alignment and positioning throughout machining, guaranteeing the correct surface is offered to the blade at the right angle. For some operations, simple vises or C-clamps are made use of. For even more intricate procedures, the device and pass away manufacturer (a machinist with specialized abilities) produces details components from design drawings.

CNC is the New Machining TechnologyCutting plastic sheet with CNC milling machine

Technology has brought better automation and also improvement to standard machining operations. A process that when took several manual modifications as well as re-positioning of the work-piece along with cautious lengthy dimension can now be performed successfully and also consistently with robotics as well as laser accuracy. This process is called CNC machining. Modern machining implies accuracy manufacturing, with the capability to transform out thousands of countless perfectly identical pieces, rapidly as well as with much less thrown away product.

As extremely technical industries have actually developed, the need for accuracy manufacturing has increased quickly. Smoother surface areas, tighter resistances, narrower cuts, as well as enhanced precision of opening placement are required for semiconductor, aerospace, fiber optic and clinical equipment. The modern technology of measurement has advanced too, making it feasible to confirm ultra accuracy machining leads to the micron level.

Pictures of a warm, dirty shop with chips flying all over could be uppermost in mind when machining is mentioned, however modern ultra accuracy CNC machining are a much more tidy and clean environment. A lot like the clean areas of semi-conductor and pharmaceutical fabrication, dirt and also international product impair coatings as well as misshape dimension in accuracy manufacturing.Wire EDM Machining center

Where older, traditional machining methods depend on sharp little bits of tungsten or carbide, modern ultra precision machining could also use electric sparks (EDM or electric discharge machining), electrochemical machining (ECM or turn around electroplating), lasers, or jets of incredibly high-pressure water to evaporate or remove product. These procedures enable the machinist to work with materials that were difficult to maker with conventional strategies, like titanium or porcelains. The contemporary approaches of precision machining make it possible to develop better devices and also jigs for standard machining too, raising efficiency for the old methods and lowering waste.

The Simple Working Mechanism and Defining Factors of the English Wheel

The English Wheel is a critical industrial tool used in the field of mechanical engineering. It is considered to be the most prudent investment that allows you to work efficiently with sheet metal.

How is it Defined?

It is a large C shaped device that is used for creating compound curves for different projects. It is this large C shape that plays a vital role in most of the industries that deal in framing and designing thin metal pieces. It is also a sheet metal fabrication device that furnishes curves to metal parts, metal sheets and/or panels made from steel or aluminum.

The most prominent work of this tool is typically found in the different types of panels of steel and aluminum that are stretched and polished to suit a variety of applications. It offers peerless flexibility in manufacturing panels with a variety of curvatures. This tool is extremely helpful in operations such as building fuel tanks, customized vehicle bodies, creating art installations and many more. In point of fact, it is also extensively used in producing prototypes of cars, bikes, airplane parts, and for small jobs like seat cowls and motorcycle tanks. In addition, they can also be used for more advanced machine in the form of a multi-station work center. All these applications stand to benefit from the implementation of this simple device.

Some Prominent Standard Factors of the Machine

1. Heavy Duty Construction

2. Quick Release Lower Anvil

3. Height 60″

4. 8″ Top Wheel

5. Throat Depth 28″

6 Weight 150 pounds

7. Floor stand, one flat anvil and 5 pieces radius anvils (2 3/8″, 3″, 5″, 8 1/2″, 12″)

8. Precision Ball Bearings

Nonetheless, in addition to these defining features, this machine can also be used for creating compound curves on varied metals like mild steel, copper, and brass.

The Working Principle

The principle of working of the English Wheel is absolutely very simple. It consists of two wheels through which a sheet of metal is extended. The lower wheel of this tool is known as the anvil wheel. As the sheet of metal passes through the two wheels, the applied pressure that is exerted by the wheeling mechanism causes reduction in the metal thickness. While the thickness of the metal keeps reducing, the metal slowly gains a curvature equivalent to the shape of the wheels that it passes through. Unlike plastics, which are formed by use of heat and pressure. The English wheel simply uses the pressure of an overhead roller to control the amount of curve put into the metals.

In this manner, the wheeling machine helps in creating curved panels in a short duration of time ensuring consistent and good results in the end. Although, it takes plenty of time to understand the entire working and handling of this high-end tool, learning the ropes of operating this machine isn’t rocket science. With proper dedication to learning and applying appropriate techniques, a fabricator can master the art of using this machine very well. Owning to all such aspects, the English wheel has emerged as the most effective and popular machine in every metal fabrication sector across the world.

FTC takes Green Lumber Seriously, American Plastic Lumber Taken to Wood Shed

FTC Takes Plastic Lumber Manufacturers to the Wood Shed for Misleading Green Claims
By Leonard Gordon and Michael S. Isselin on July 21, 2014

While enjoying these lovely summer days, did you ever wonder how many milk jugs or detergent bottles went into making that “green” picnic table you’re sitting at? You may now. The already peculiar concept of “plastic lumber” is further complicated when manufacturers make false statements about its contents. As new products emerge touting environmental attributes, the FTC continues to warn manufacturers, distributers, and marketers of environmentally-friendly products against misleading consumers as to how “green” the product is.

In two recent cases, the FTC took aim at a plastic lumber marketer and a manufacturer, both advertising and marketing products said to be made (almost) entirely of recycled plastics. Both companies have now settled with the FTC and are prohibited from making such misleading representations.

American Plastic Lumber and FTC

On Thursday, the FTC settled with Engineered Plastics Systems, LLC (“EPS”), a manufacturer, advertiser, and distributer of plastic lumber products such as picnic tables and benches. In its complaint, the FTC alleged that EPS’s advertisements and marketing materials deceived consumers into believing the plastic lumber products were made entirely of recycled plastic. For example, the materials read “Made entirely of recycled plastic lumber” and “All recycled plastic design.” According to the FTC, these representations would lead the average consumer to believe that the products were composed entirely of, or almost entirely of, recycled plastic, however, the FTC found that the products contained an average of only 72 percent recycled plastic. This deceptive and misleading conduct, in violation of the FTC Act, put EPS in hot water with the FTC.

Under the settlement, EPS is prohibited from making similar claims that deceive consumers, and EPS must ensure claims are true, not misleading, and substantiated by proper evidence before stating information about recycled contents or environmental benefits of a product (or packaging). Additionally, EPS may be required to provide scientific research to verify its claims, and must give evidence that the materials used were taken from the waste stream according to the FTC’s “Green Guides for Environmental Marketing.”

The EPS settlement came less than a month after the FTC settled a similar case with American Plastic Lumber, Inc. (“APL”). Like EPS, APL distributes plastic lumber products such as picnic tables, benches, and speed bumps. APL hit a speed bump of its own after the FTC alleged its advertising and marketing materials deceived consumers into believing the products were made of virtually all recycled plastic. In fact, APL’s products averaged less than 79 percent of recycled plastic, and the FTC found no recycled content at all in nearly eight percent of APL’s products.

Similar to EPS, the settlement prohibits APL from making false representations about the recycled content of its products unless it is true, not misleading, and is backed up with evidence. APL is also required to maintain and make advertisements and marketing materials with claims covered by the settlement available to the FTC for five years.

These cases confirm that Green Claims remain a priority at the FTC. As “green” products continue to hit the market, the FTC continues to enforce its “Green Guides” and pursue “green” claims through consent orders with the violating companies without providing consumer redress. To avoid deceptive pitfalls, companies advertising and marketing products with recycled content should carefully review the FTC’s “Green Guides.” Otherwise, you might end up in the FTC woodshed.

Huge New Acetal Rod Produced By Gehr Plastics

Gehr Plastics Throws Down The Gauntlet

Huge new Acetal Copolymer Rod is over 24″ in diameter, a full 600mm. This is the largest Acetal rod now made in the World.

Huge Acetal Copolymer Rod, Over 24

Read about this large plastic rod material in the Press Release about ‘Huge Acetal Rod’.

For years, the major producers of Acetal rods have been ‘competing’ for the title of ‘Largest Acetal Rod’. Last year, Z/L Plastics started their production of 500mm or 19.75″ diameter Acetal Homopolymer and Acetal Copolymer Rods. These were the biggest materials available in the marketplace until this months news from Gehr Plastics. They announced this record size production at this years IAPD 2015 convention in San Diego (Sept 22 – 25, 2015).

Many ask ‘Why would anyone need Acetal Rod in this large of a diameter?”, and the answer is that producing a round finished part from rod is much cheaper and environmentally friendly than cutting from sheet stock. Cutting a round part from a flat sheet wastes over 35% of the material, and requires much more machining time. It is always best to investigate the best sizes of materials before beginning the machining process. Plastics manufacturers now make a huge range of plastic sheets, rods and tubes, which enable the end user to pick the most appropriate size for a specific application with the least amount of waste.

There are many excellent suppliers of these materials, and some truly fine experts with great insight into the industry. Consider not only looking at large suppliers, perhaps the best suppliers are those that care about providing informing and educating clients. The Plastic Mentor blog boasts the most experienced ‘Plasticologists’ in the industry, and offer dozens of insightful articles to assist those looking for the proper plastic materials. Other sites focus on specific types or grades of materials, including High Tech Plastics which is an online store for performance plastics in full sizes, cut to size and remnant pieces of the high end plastic materials.

It is best to do a fair amount of research prior to making a decision. With over 80 common performance plastics available, and dozens of sizes in several shapes, the width and breadth of materials in massive. Ask the experts for assistance, most offer toll free numbers directly to the most experienced and trained plastic experts.

Topic: Huge Acetal Copolymer Rod by Gehr Plastics