Components, once manufactured, are passed through different surface finishing processes, for which chrome plating is also opted.

These surface finishing processes always enhance the durability and look of the component. If you want to learn about chrome plating, you can go through this guide below.

What is Chrome Plating?

Chrome plating is a method in which a layer of chromium is applied to a metal through electroplating. This process improves the durability and toughness of the component and also makes it corrosion-resistant.

The Chrome Plating Process

Chrome plating is a step-by-step process, and the section below details it.

• The first stage involves cleaning the component by degreasing it using an abrasive cleaner. It helps eliminate dirt, grease, or any other impurity on the surface.
• The component to be chrome plated is mounted on a fixture that can conduct electricity, and it is connected to the circuit for the process.
• An electro-cleaning solution is added, and the component is submerged in it. The component is then connected to the power supply. When the current passes, the residual impurities are removed.
• The component is then introduced to a chromic acid bath in the presence of electricity, and chromium ions deposit on the surface, creating a chrome layer.
• The component is then rinsed so that any residue of the chemicals is removed.
• The chrome-plated component is then polished and buffed to achieve the desired finish and is inspected thoroughly.

Benefits of Chrome Plating

Chrome plating offers versatile benefits, and some of these benefits are as follows:

• Hard chrome plating offers hardness, which is more than metallic coatings, and can withstand high stress.
• The addition of a thick layer of chromium plating protects the components from wear and tear when they are exposed to chemicals.
• Hard chrome plating, when it comes in contact with graphites, metals, and polymers, tends to have less friction and hence is suitable for moving parts.
• When the chrome plating gets damaged, it can be replaced easily and the lifespan of the parts can be enhanced.

Key Types of Chrome Plating

There are different types of chrome plating, and some of these are as follows:

Hard Chrome Plating

Hard chrome plating is the application of a thick chromium layer to the steel component. This electroplating process involves submerging the component in chromic acid and depositing a layer of chrome.

Hard chrome plating enhances the life of the components and enhances their resistance against corrosion. It even helps with oxidation resistance and chemical inertness.

Decorative Chrome Plating

Decorative chrome plating, as the name suggests, enhances the aesthetic beauty of the components. It is a thin layer and, hence, less durable.

The process of decorative chrome plating starts with nickel electroplating and sometimes even copper plating. It adds smoothness and reflectiveness before the chrome plating.

Thin Dense Chrome Plating

Thin dense chrome plating is a coating that is used in manufacturing applications.

The chromium material is electroplated on the components and has a surface texture that is microcracked and micronodular. This coating enhances the life and operational efficiency of the components.

Suitable Materials for Chrome Plating

Chrome plating can be carried out on various materials, but the main materials usually opted for chrome plating are as follows:

Steel

Steel is a very common material which is used in different industries. After adding a layer of chrome plating, the steel components became durable, and resistant to wear and corrosion.

Aluminum

Aluminum is mostly chosen because it is strong and lightweight. Therefore, in heavy-duty applications, aluminum proves to be a suitable choice.

When aluminum components are chrome-plated, they become resistant to corrosion and durable. Automobile parts like wheels and trims, and even aerospace components made using aluminum, are chrome-plated.

Plastics

All types of plastics are not good conductors of electricity, but some of them, like ABS, can be chrome plated. It is used in the electronics and automobile industry and can offer a metallic look, being lightweight due to chrome plating.

The interior and exterior of cars and various household items manufactured using ABS are chrome plated.

Applications of Chrome Plating

Chrome plating is observed in different industries, and some of these are as follows:

Automobile Industry

Chrome plating is used in the automotive sector for functional and decorative purposes.

The components of vehicles, like trims, grilles, bumpers, and exhaust, are all chrome-plated. The reason behind their chrome plating is to enhance the resistance against wear and tear and give them a shiny look.

Aerospace Industry

The aerospace industry needs strength-oriented components that are heat-resistant and lightweight. Hence, aluminum and steel, which can be chrome-plated, are commonly used in this industry.

The chrome-plated aerospace components can resist friction and corrosion and even withstand stress. Components like engine parts, landing gear, and hydraulic systems are chrome-plated.

Medical Industry

Chrome plating is also used to add a protective layer to medical components and surgical tools. It helps to enhance the durability and sterilization of these components.

The chrome-plated tools are highly corrosion-resistant and can withstand chemical use and sterilization.

Conclusion

The finishing process of chrome plating gives the components new life and protects them with a protective layer. These components have a durable life span and can be used for different applications.

Start Your Chrome Plating Project with DEK

Are you starting a new project requiring chrome plating on the components? DEK can be your go-to choice as we offer high-quality secondary finishing processes, and chrome plating is also one of them.

So, give us a chance to enhance the properties of your components by adding a chrome layer to them.

FAQs

Is chrome plating expensive?

Compared to other electroplating processes, chrome plating is a little expensive as it is a complex process.

How to remove chrome plating?

Chrome-plated components can be submerged in hydrochloric acid to remove the plating.

How is chrome plating done on aluminum?

Aluminum components are first copper-plated and then subjected to the chromium-plating process.

What’s the difference between hard chrome and decorative chrome plating?

Hard chrome plating is thick and focused on the performance and function of the component. Decorative chrome plating is thinner and less durable. It enhances the look and aesthetics of the parts.

What types of chrome plating should you choose?

Every type of chrome plating has a different purpose. The decorative chrome plating is used for coating the decorative components whereas the hard chrome plating is used for a durable life.

Based on your application requirements, you can choose the type of chrome plating.

Are you planning to start a new project with glass-filled nylon and want to learn about it? You are at the right place then.

Glass-filled nylon is a material used in different applications for its versatile characteristics. This guide below has the answers to all your questions about glass-filled nylon, so let's read.

What is Glass Filled Nylon?

Glass filled nylon is a combination of nylon and glass. It is nylon with glass reinforced on it. It is known for various properties found in glass and nylon. It exhibits mechanical damping followed by excellent creep resistance.

It is also opted for the improved heat distortion temperature it offers. When glass fibers are mixed with nylon resins, a composite material is formed.

It is used for components that are high-performing. The glass fibers used in the material range between 10 to 40% of the total weight.

Properties of Glass Filled Nylon

Glass-filled nylon has been chosen for different projects due to its excellent properties. Some of its properties are as follows:

• Glass-filled nylon offers excellent strength and fatigue resistance.
• It does not deform easily and is also warp-resistant due to its low thermal expansion.
• Glass-filled nylon can work under a wide temperature range and maintains its dimensional stability as well.
• It offers seamless creep resistance, and even when subjected to mechanical pressure, it prevents deformation.
• It is highly shock absorbing and can even resist vibration, so it is suitable for applications that are vibration-sensitive.

Advantages of Glass Filled Nylon

Glass-filled nylon offers multiple benefits, which is why it is used in many applications, and some of these are as follows:

High Moldability

Glass-filled nylon can be molded in versatile shapes and designs, regardless of its complexity. It can be used for injection molding, and the required product is achieved.

High Electrical Insulation

Glass-filled nylon has seamless electrical insulation. It is, therefore, used for electronic component manufacturing.

Enhanced Strength

It has high tensile strength and an enhanced modulus of elasticity, which makes it suitable for applications that require load-bearing capacity and structural integrity.

Excellent Impact Resistance

The glass and nylon combination improves cracking resistance and allows it to handle more pressure. Hence, applications that involve dynamic loading find it suitable.

High Dimensional Stability

The addition of glass fibers in the nylon lowers the coefficient of thermal expansion. It also makes the material dimensionally stable.

Hence, there is a reduced chance of warping, expansion, or shrinking due to the changes in temperature.

Disadvantages of Glass Filled Nylon

Glass-filled nylon has ample benefits, but there are some downsides of it, too, which are as follows:

• Glass-filled nylon has a higher weight, which is about 15% more than nylon, which makes it unstable for low-weight applications.
• It has anisotropic properties, which cause misalignment of glass fiber in the machining process, leading to varied stiffness through different axes of the component.
• The impact of glass fiber on the mating surface may be abrasive, and hence, it is not suitable for sliding applications.
• It absorbs moisture, which is why structural weakness is observed in it when subjected to wet environments.
• It's expensive compared to the unfilled nylon in most cases.
• It is highly brittle, and under a high-stress environment, it may fracture or crack.

How is Glass-Filled Nylon Used in Parts Production?

The process of manufacturing glass-filled nylon is discussed below.

CNC Machining

CNC machining is a very ideal process when it comes to manufacturing components using glass-filled nylon.

It is, however, suggested that carbide-based cutting tools be used when machining glass-filled nylon due to its abrasive properties. Moreover, during machining, it is suggested to even work on low cutting speed, which also offers optimal cuts with low tool wear.

3D Printing

3D printing is an additive manufacturing process that utilizes glass-filled nylon and manufactures 3D components. The process works by adding layer after layer using different 3D printing methods.

The nozzles for 3D printing that work with glass-filled nylon should be made of hardened steel to deal with the abrasive nature of the material.

Injection Molding

The injection molding process uses different types of glass-filled nylon. The material offers high abrasion. Hence, the materials used for injection molding tools must be able to deal with this abrasion and are preferred to be made using hard steel.

Common Types of Glass-Filled Nylon

There are different grades of glass-filled nylon, and each type has its own properties and uses. Some of these common grades of glass-filled nylon are as follows:

PA 6/6 GF

PA 6/6 GF has about 15 to 50% glass material, and it has excellent impact resistance, rigidity, and thermal properties. It also has good thermal stability and moisture resistance.

Hence, it is widely used in precision-oriented applications and load-bearing parts like machine components and pulleys.

PA 6 GF

PA 6 GF has a ratio of glass of about 15 to 45% combined with nylon 6. The addition of glass fiber improves the impact resistance, moisture absorption, and mechanical performance of the material. It is then used in engine guards and plastic enclosures.

PA 12 GF

PA 12 GF has PA 12 as a base material, and its glass is enforced in a ratio of up to 30%. It offers high chemical resistance and also has a low melting point with limited strength.

However, it is suitable for such applications which require stable chemical properties rather than mechanical ones.

PA 46 GF

PA 46 GF is high-performing glass-filled nylon. It has high wear resistance and excellent thermal stability. It is suitable for most applications, like making circuit breaker components for electric motors and sensors.

PA 6/6 GF FR

PA 6/6 GF FR has flame-retardant properties. Hence, it is suitable for applications in which safety from fire hazards is needed. It is mostly used in appliances and electrical circuits.

Applications of Glass Reinforced Nylon

There are many applications of glass-filled nylon, and some of these are as follows:

Industrial Applications: It is used in industries for manufacturing different parts like pipes, valves, bushings, conveyor belts and other components for machinery.

Automobile: The glass filled nylon is used in the automobile industry to make car components like gears, fan blades, fuel tank caps, and latches.

Electronics: Glass-filled nylon is used for earphones, printers, cameras, printer cartridges, and other electronic components.

Household: It is suitable for households manufacturing consumer products like vacuum cleaners, water purifiers, combs, and other appliances.

What’s the Difference Between Nylon 12 and Glass-Filled Nylon?

Glass-filled nylon is a nylon material that consists of glass fibers, making it stronger than nylon. It has high rigidity and is hence suitable for components that need excellent mechanical performance.

Nylon 12, on the other hand, offers impact resistance, mechanical strength, and resistance against chemicals. However, it has low friction and moisture absorption, which makes it work well in humid environments.

Get Machined Glass-Filled Nylon Parts at DEK

Glass filled nylon has versatile uses in different industries, and if you are looking for machine components made of glass filled nylon, you can contact DEK.

We design and manufacture custom glass filled nylon components for your projects as specified by you. We have advanced manufacturing processes, high-quality materials, and expert engineers.

Conclusion

As you have read the guide above, it would have been sufficient to help you with your new project related to glass filled nylon.

It is very crucial to understand the properties, manufacturing processes, and applications of this material before you choose it for your projects.

FAQs

How does glass-filled nylon compare to unfilled nylon?

Glass-filled nylon offers better strength, creep resistance, and dampening properties compared to unfilled nylon.

Is glass-filled nylon stronger than polymer?

Yes, glass-filled nylon offers superior strength compared to polymer.

How do you choose glass-filled nylon grade for machining applications?

Glass filled nylon is hard and strong with a high glass-fiber ratio, but the harder it is, the more difficult it is to machine.

What safety precautions are important when machining glass-filled nylon?

Glass-filled nylon, when machined, produces a lot of dust which can contaminate the environment of the workshop. It requires proper filtration and ventilation when machining it.

Aluminum has special physical and chemical properties, not only light weight, strong texture, corrosion resistance, and has good ductility, electrical conductivity, thermal conductivity, heat resistance and resistance to nuclear radiation, is the development of the national economy of the important basic raw materials, aluminum and aluminum alloys are widely used in various industries.

If you are considering aluminum die casting for your upcoming projects and want to learn about this process in detail, read the guide below.

What is Aluminum Die Casting?

Aluminum die casting manufactures lightweight aluminum components that have complex shapes and thin walls.

Aluminum has the ability to withstand corrosion resistance, and it even offers high electrical and thermal conductivity. It is a process that helps retain the strength of aluminum die-casted components even at extreme temperatures.

The aluminum die-casting process has been used for a long time, and the first aluminum die-casting was done in 1800 using pressure injection. In 1849, the first machine for die casting was manufactured. However, it was manually operated.

After 20 years, the development of that die casting printer was enhanced. It was used for different components manufactured in high volume by 1900.

How Does It Work?

The process of aluminum die casting is carried out in multiple steps, and these are as follows:

• Aluminum bars are first heated at high temperatures until they melt. At the same time, a cold chamber setup is also used to avoid machine damage.
• The molten aluminum is kept in a melting pot away from the casting machine. It is then ladled from the pot into the die of the machine under high pressure.
• The aluminum in liquid form, after melting, is injected into the mold, and until solidified, it is left to rest.
• The two halves of the die are separated to eject the solidified aluminum component.
• The aluminum die-cast components might need the additional process of finishing so that the required surface finish is achieved.

Advantages of Aluminum Die Casting

The process of aluminum die casting is opted for because of the benefits it offers. Some of these benefits are as follows:

• This process manufactures components that have a smooth surface finish.
• It offers excellent tensile strength, and the cost of raw materials is low.
• The molecular structure of the components manufactured through die casting is firm and doesn't get cracks under pressure.
• It offers a thickness accuracy of less than 1.5.
• It offers durability and can produce complex shapes.
• The chemical and mechanical properties of aluminum die-casted components are excellent.

Types of Aluminum are Used for Die Casting

The aluminum alloys commonly used for die casting are the following:

• A390
• A380
• A413
• A360
• ADC-1
• ADC-12

The most important part of aluminum die casting is picking the right aluminum alloy. The A390 alloy offers excellent resistance against wear and is hard, but it is less flexible too. It can be used for engine blocks in automobiles.

A360, on the other hand, has excellent corrosion resistance and pressure tightness. When in the molten form, they are highly fluid and opted for oil pans of cars, 5G communication boxes, etc.

A380 alloy has seamless casting properties, and it can be used for household furniture and power tools.

Surface Finish Options for Die-Cast Aluminum

Die-cast aluminum can be treated with various surface finishing processes, and these are the following:

Anodizing

Anodizing is a cost-effective process that enhances the corrosion resistance of the components that are manufactured using aluminum die casting. It even enhances the durability of the components and adds a protective layer that is non-conductive.

Aluminum anodizing is used to build an oxide layer, which makes it non-conductive. Hence, it is suitable for applications where electrical conductivity is not needed.

Powder Coating

Powder coating is one of the widely opted processes for finishing the surface of aluminum components, which are manufactured through die casting.

This process is conducted in high temperature conditions and enhances the scratch resistance of the components. This process allows for having different gloss finishes, textures, and colors on the components.

Chem Film

Chem film is applied using various methods like dipping the component, brushing, or spraying. It offers high electrical conductivity to the aluminum die-casting components.

Applications of Aluminum Casting Parts

The aluminum die-casting components are widely used in many applications, and some of these applications are as follows:

Construction

In the construction industry, aluminum die casting helps manufacture frames for windows and roof structures. It is very commonly used in commercial buildings and bridges.

Automobile

Aluminum alloys are high strength, and their weight is less, which makes them fuel-efficient when used in vehicles. Hence, the automobile industry uses these alloys in various applications ranging from body parts to the engine of the car.

Electronics Industry

Aluminum plays a vital role in manufacturing electronics with innovation. These electronics are produced using die-cast aluminum, which can be used in 5G network housing and smartphones.

Furniture

The furniture industry uses aluminum due to its high strength, low weight, and ability to resist corrosion. The components are low-cost and, hence, can be easily used for affordable furniture.

Chairs, locks, knobs, and other fittings in the furniture industry are manufactured using aluminum die-casted components.

Factors to Consider in the Design of Aluminum Die Casting Parts

When designing components using the process of aluminum casting, some of the factors that should be considered are as follows:

Design of Mold

The design of the mold needs to be perfect and efficient so that the aluminum parts come out perfectly. The mold has a parting line that divides it into two halves, and this should be considered when creating the components.

Injection Point Location

When the molten aluminum is injected into the mold, the point of injection must be carefully considered. It should be poured accurately, ensuring that it fills the cavity property because sometimes the solidification of metal takes place very quickly, leading to uneven texture.

Thickness of Wall

The thickness of the wall component is also very important to consider. It is important that you go for a consistent thickness which ensures uniformity in the component.

Conclusion

The guide above has all the important details regarding aluminum die casting. You can now start your project keeping in mind all these aspects and how you can have a seamless aluminum component.

Start Your Custom Aluminum Die Casting Prototypes and Parts with DEK

If you are looking for help in your aluminum die-casting project, we at DEK can assist you. We have years of experience manufacturing aluminum components using die-casting processes.

We also ensure that we provide you with custom components based on your specifications. So, get in touch with us today and help us cater your projects.

Elastomers of different types are used in manufacturing a wide range of components. Sometimes, they are also used for making prototypes.

If you are looking forward to learning about elastomer prototyping, the guide below is the key to the details.

What is Elastomer?

Elastomers are polymers which offer elasticity and viscosity.

Elastomer molecules can be joined together with the help of weak intermolecular forces that offer high yield strength and low Young's modulus.

Elastomers have the ability to gain their actual shape again after they have been stretched.

Types of Elastomer

There are two types of elastomers, and each type has its properties, as discussed below.

Saturated Elastomer

Saturated elastomers offer stability against ozone, radiation, heat and oxygen. These are not curable by sulfur vulcanization and have less reactivity.

Silicone and polyacrylic rubbers are the types of saturated elastomers.

Unsaturated Elastomer

Unsaturated elastomers are capable of being cured with the process of sulfur vulcanisation. The types of unsaturated elastomers are composed of natural polyisoprene and butyl rubber.

Methods to Produce Elastomeric Prototypes

There are different methods which can be used to produce elastomer prototypes, and these are as follows:

CNC Milling

CNC milling is a process in which the software instructs tools of a CNC machine to shape and cut the elastomers.

The nature of elastomers is highly flexible, and this requires a lot of care during the machining process.

It is very important to avoid deformation by choosing the right speed of cutting tools and cooling methods.

The process of CNC milling is suitable for such prototypes of elastomers that need high accuracy, complex geometries, and intricate details.

It is usually opted for low-volume production of elastomer components.

Injection Molding

Injection molding also helps manufacture elastomer prototypes in larger quantities. The elastomers are melted and injected into the mold, which has already been manufactured beforehand.

Once the molten elastomer has cooled down and solidified, it is demolded.

The process of injection molding can be repeated multiple times to manufacture more components of the same design.

It is very easy to manufacture prototypes of different elastomers using injection molding. The cost of mold, however, is high, and hence it is suitable for high volume production.

3D Printing

3D printing deposits the material layer by layer to create a 3D component. Elastomer materials can also be used for manufacturing properties using 3D printing.

The process is flexible and offers quick changes with no expenses whenever needed in the design. Hence, this process is suitable for short runs and rapid prototyping.

It helps to create complex components and that too very quickly.

Design Considerations Of Elastomer Prototyping

When carrying out elastomer prototyping, there are a few design considerations that play a vital role, and these are as follows:

Material

When designing the prototype of elastomers, the right type of elastomer should be chosen for the application. The hardness, flexibility, strength and elongation are the aspects to consider.

Moreover, the compression ability of the material should be assessed to ensure it retains its original shape over time.

Wall Thickness

The thickness of the wall when manufacturing a prototype using an elastomer is important to maintain. When doing processes like injection molding, inconsistent thickness may lead to warping.

Hence, the thickness of the walls must be accurate. The thin walls lead to deformation and thick lead to improper filling.

Complex Shapes

If the design has complex geometries, the elastomer prototyping can be challenging. It could lead to difficulty in ejecting the component and deformation.

In this case, the use of flexible inserts, draft angles and multi-part molds can be helpful.

Consider Shrinkage

Elastomers have a tendency to shrink once cured or molded. Hence, when designing a prototype using elastomers, consider the shrinkage.

Moreover, sometimes it gets very difficult to maintain tolerance with elastomers due to high flexibility; hence, setting realistic expectations is important.

Surface Finish

The surface finish of the elastomers plays a vital role in aesthetics as well as functionality.

Hence, it is important to have a smooth finish to help reduce friction. At the same time, a textured surface helps enhance grip.

The finishing of the prototypes also impacts the way elastomers interact with coatings. Hence, a finish should be chosen with the balance of performance and appearance in mind.

Start Prototyping Rubber Parts Efficiently with DEK

DEK offers to manufacture prototypes of rubber parts using different manufacturing processes.

We analyze the type of elastomers you want to use and choose the most relevant manufacturing process.

We have a team of expert engineers to offer their expertise in the manufacturing process of your components. So, get in touch with us to make the best of our prototyping services.

Conclusion

Understanding details about elastomers, processes involved in prototyping them, and their types is very crucial before you use them in your projects.

As you have read the guide above, every detail regarding the material must be clear allowing you to make informed decisions.

Aluminum is a widely used versatile material that has many grades. 7075 aluminum is also a very commonly opted grade, which has multiple applications and properties.

If you are looking to use 7075 aluminum in your projects and want to learn about it, read the guide below.

What is Aluminum Alloy?

Aluminum alloys are metals that have aluminum as the prime metal, followed by other elements like tin, copper, magnesium, etc. The combination of these alloying elements with aluminum creates a new grade that modifies the structure and properties of the aluminum.

Composition of 7075 Aluminum

Aluminum 7075 is an aluminum alloy which has the following alloying elements:

• 87 to 91% of aluminum
• 5 to 6% of zinc
• 0-0.3% of manganese
• 1.2 to 2% of copper
• 2.1-2.9% of magnesium
• 0-0.5% iron
• 0.0-0.2% titanium
• 0.18-2% chromium
• 0.05-0.15% other types of elements

These elements, when added to aluminum in such small amounts, modify the properties of aluminum and make it suitable for different applications.

Properties of Aluminum 7075

Aluminum 7075 has the following properties:

• It has a density of 2.81 g/cm3 and a tensile strength of 228-572MPa; the yield strength is 103-503MPa.
• The modulus of elasticity ranges between 71.7 to 72.4 GPa, and Brinell hardness is 60-150.
• Shear modulus is 26.9-27 GPa, and elongation at break is 5% to 19%. The shear strength is 152-331 MPa, and the fatigue strength is up to 159 MPa.
• Aluminum 7075 offers a thermal conductivity of 130-173 W/mK and a specific heat capacity of 0.96KJ/kg°C.
• It has a melting point of 477°C.
• Aluminum 7075 has moderate corrosion resistance and high machinability, but it does not possess good weldability.

Advantages of Using Aluminum 7075

The advantages of opting for aluminum 7075 for the different projects are as follows:

• Aluminum 7075 offers a high strength-to-weight ratio.
• It works well under stress due to its high fatigue resistance. Therefore, applications where components are subjected to pressure may find aluminum 7075 suitable.
• Aluminum 7075 is highly machinable and can be opted for manufacturing components.
• Aluminum 7075 is not highly corrosion resistant, but some of its tempers, like T73, are suitable for marine and outdoor applications.
• It has a high modulus of elasticity and offers to be dimensionally stable.

Limitations of Aluminum 7075

Aluminum 7075 offers benefits but also has some limitations; some of these limitations are as follows:

• Aluminum 7075 has limited weldability and requires special techniques for welding, also, it has a tendency to crack during the process of welding.
• When compared to other aluminum grades, aluminum 7075 offers limited corrosion resistance and hence cannot be used in moisture-based environments unless treated.
• Aluminum alloys, apart from 7075, are quite affordable, whereas 7075 is very expensive and cannot be a suitable choice for budgeted projects.

Manufacturing Process of Aluminum 7075

The manufacturing process of aluminum 7075 involves different techniques, and the three most popular methods are given below.

CNC Machining

CNC machining of 7075 aluminum uses a process of manufacturing controlled by software. A block of aluminum 7075 is used, and the cutting tools allow for the shaping and manufacturing of components.

Aluminum 7075 offers good machinability and tends to produce highly precise components. Applications that need aluminum 7075 components with tight tolerance opt for CNC machining.

Aluminum Extrusion

The aluminum extrusion process helps manufacture components from aluminum 7075. In this process, aluminum is heated and forced through a die so that components with the shape of the die are created.

The process is suitable for manufacturing multiple components with consistency and a long structure. This process offers components with improved mechanical properties and is cost-effective.

Die Casting

Die casting process consists of injecting the aluminum 7075 in molten form into the molds using high pressure. Once the material has cooled down and solidified, it takes the shape of the mold.

The components manufactured through die casting offer consistent quality and are usually complex in shape.

Comparing Aluminum 7075 with Other Alloys

There are different alloys of aluminum, and comparisons of aluminum 7075 with those alloys are given below.

Aluminum 7075 vs. Aluminum 6061

Aluminum 6061 is also known as structure aluminum and is used in the construction industry. It is mostly opted for the purpose of extruding pipes, tubes, aluminum bars, etc. It is a versatile material and is opted for heat sinks and bicycle frames.

Compared to 7075, it has better corrosion resistance, high machinability, and is even weldable. However, the strength of 6061 is not as good as that of 7075.

Aluminum 7075 vs. Aluminum 2024

Aluminum 2024 is popular in aerospace applications and is opted for fuselages and wings of an aircraft. It is durable and is chosen for applications that need cyclic fatigue resistance.

7075 aluminum, on the other hand, is suitable for applications that have a high-strain and pressure environment. The two of these do not offer high weldability and even have the same machinability.

However, 7075 has better corrosion resistance, whereas 2024 has better workability.

Applications of Aluminum 7075

The applications of aluminum 7075 can be seen in different industries; some of these applications are as follows:

Aerospace: It is used in wings, fuselages, and structural components of aircraft due to its high strength-to-weight ratio.

Automobile: In the automobile industry, high-performance vehicles are mostly opted for to manufacture their components like chassis, driveshafts, and suspension parts.

Marine: Marine applications also use aluminum 7075 but require some additional coatings so that marine components made of aluminum 7075 resist corrosion.

Tools and Molds: Aluminum 7075 offers high strength, which is suitable for manufacturing tools, dies and molds for different manufacturing processes.

Conclusion

When selecting aluminum 7075 alloy, understanding its properties proves to be highly significant.

As you have gone through the guide, you must now know important details about aluminum 7075. If you need to have aluminum 7075 components manufactured with high accuracy, contact us at DEK.

Screws play a vital role in all types of projects, and you can have custom micro screws designed.

If you are planning to come up with a new project and want to learn about micro screws, the guide below has all the information regarding custom micro screw manufacturing.

What are Custom Micro Screws?

Custom screws are used in applications where standard screws cannot be used. These custom micro screws cater to the unique requirements of the project.

These screws are suitable for precision-oriented applications like aerospace, electronics, and medical. These industries cannot tolerate even a minor deviation.

These custom screws are made using versatile materials which cater the application requirements like corrosion resistance, weight considerations, and durability. These screws even ensure aesthetics and integrity.

Benefits of Custom Micro Screws

Custom micro screws are used widely in many applications; some of the benefits of custom micro screws are as follows:

• Custom micro screws are designed so that they meet the precise requirements of applications for which these are used.
• The custom micro screws can be optimized to meet the specific resistance to wear, corrosion and offer required strength.
• The custom micro screws can be made with versatile materials; these materials are chosen based on the environment they are opted for use. For instance, stainless steel micro screws can be chosen for an environment exposed to corrosion and high temperature.
• Certain industries need to fit very small components with perfection. Hence, these custom micro screws can be designed in the tiniest size to cater for precision.
• As they have the exact dimensions required for the application, the final product tends to have better performance and quality.

6 Drive Types for Custom Screws

The six drive types for custom screws which are commonly opted for are as follows:

Phillips Drive

Phillips drive has a cross-shaped slot, which is used for self-centering characteristics. The chances of slippage are very less in this type of screw. It is suitable for automated production lines and is also used in consumer electronics.

Torx Drive

Torx drive has a pattern of star shape. It has high torque transmission and less risk of cam-out. It is suitable for applications that require high precision, such as electronics and aerospace.

Slotted Drive

Slotted drives have a straight slot and have a very simple operation, but they can cam out. These are used in applications that need precise control of torque.

Tri-Wing Drive

Tri-wing drive has a slotted pattern in a triangular pattern and is used in applications that need tamper and stress resistance. It is commonly used in electronic devices that have a high control over access for adjustments and repairs.

Allen Drive (Hex Socket)

Allen drive has a hexagonal socket and works with an Allen key. It offers excellent torque and is used in automobile and machinery applications.

Robertson Drive (Square Recess)

Square recess offers cam-out resistance and a high capacity of torque. It is very commonly used in construction and woodworking as it is easy to use and holds strongly.

Custom Micro Screws Head Styles

The head style designed in custom screws requires balancing the screw fist and meets the specific application requirements. The head style should meet the space, torque, and ease of assembling requirements.

Moreover, the head style must have an aesthetic appearance in applications where they are visible. The main goal is to create a screw head that meets the design requirements, ease of use, and mechanical needs of the product.

Material Selection of Custom Micro Screws

The material of custom micro screws plays a vital role in performance and durability. Based on the environment it will be exposed to, the material is chosen for these screws. Some of the commonly adopted materials are as follows:

Metals

The different types of metals are commonly chosen for the micro screws; some of these metals are as follows:

• Stainless steel is a highly corrosion-resistant material that is suitable for applications that are exposed to moisture or outdoors.
• Aluminum is a lightweight material and is suitable for applications that are weight-sensitive.
• Brass is also resistant to corrosion and offers moderate strength. It is heavier than aluminum but not as heavy as steel. It is chosen for decorative purposes.

Plastics

• Nylon is suitable for insulation and also is lightweight. It offers chemical and corrosion resistance and works well in light-duty applications.
• Polycarbonate has excellent resistance against impact and corrosion and is used in applications that need transparency and lightweight screws.
• PVC is highly corrosion-resistant and soft and is used in plumbing applications as it resists chemicals and water.
• ABS is extremely strong and lightweight and, hence, can work in electronics and automobile applications.

The Importance of Precision in Size and Tolerance

The custom micro screws need to be highly precise and tolerant for the sizes; a minor deviation may lead to issues with their performance. Hence, the tolerance of these screws must be very carefully adjusted.

These custom micro screws are mostly used in sensitive applications like aerospace, electronics, and medicine.

The manufacturing process for these screws needs to be highly precise and consistent. The accuracy of these screws offers successful projects as they work with effectiveness.

Threading and its Impact on Micro Applications

The threading of custom micro screws is also vital for their functionality as it determines their fitting into different applications. The aspects like depth, pitch, and influence of profile are very important; they reflect the way the screw interacts with the material.

Industries like medical and microelectronics are highly precise industries, and they prefer fine threads for the micro screws.

These screws ensure a very strong grip and also secure the materials very well. The design of the thread also impacts the way screws can be fixed and removed.

The load distribution is also affected by the threading of the screw, and it impacts the wear resistance, durability, and strength in applications where they are used repetitively.

Manufacturing Method of Custom Micro Screw

The manufacturing process of custom micro screws varies based on the material and applications. Some of the commonly opted micro screw manufacturing processes are as follows:

CNC Machining

CNC machining is one of the most precision-oriented methods which helps to manufacture micro screws. The process works using CNC-controlled machines, which have highly accurate and detailed manufacturing capabilities.

The block of material is carved to manufacture the micro screw based on the custom design. This process helps manufacture micro screws with tight tolerance, and industries like aerospace and medical use it.

Swiss Screw Machining

Swiss screw machining or Swiss turning is a machining process that helps manufacture micro screws with the help of a lathe.

The workpiece is fixed and rotated, allowing the lathe to cut the workpiece and derive the micro screw. The micro screws that have complex geometry are usually manufactured through this process.

Thread Rolling

The thread-rolling process creates threads on the micro screws. The process starts by pressing a die that is shaped on the workpiece and rotates. The process helps to create strong threads and offers fatigue resistance.

Cold Heading

The process of cold heading involves a metal wire which is cut into the given length, and then a screw shape is formed at room temperature.

This process is suitable for producing custom micro screws in mass volume, and it offers strength to these screws with work hardening. These micro screws are mostly used in the automobile industry.

Micro Injection Molding

The process of micro injection molding helps in producing micro screws that are manufactured using plastics.

The process of injection molding works by injecting molten plastic into the mold, which is left for solidification. The process is suitable for manufacturing plastic screws which are highly precise and suitable for the electronic industry.

Applications of Custom Micro Screws

Custom micro screws are used in many industries, and some of their applications are as follows:

Electronics

Electronics are of varied sizes, and each of them requires different screws to fix components. Microelectronics usually need micro screws as they can easily align the components.

Some of the devices like mobiles, tablets, circuit boards, and smartwatches are assembled using micro screws.

Medical

Micro screws are used in the medical industry for assembling surgical tools, orthopedic implants, dental implants, and even in diagnostic equipment. The precision of these micro screws tends to cater to the medical industry with highly accurate fixation.

Aerospace

The aerospace industry requires custom micro screws, which are strong, lightweight, and precise; aircraft components and satellites tend to have these.

Automobile

Micro screws help in fastening electronic systems and sensors of the engine. They are especially used in motorcycles, racing cars, and electric vehicles, as precision is significant here.

How to Balance Cost and Quality?

Custom micro screw selection is successful when there is a balance between quality and cost. The low-cost screw helps save upfront costs, but in the longer run, the high cost of maintenance and failure risk is present.

Whereas, when you invest in high-quality screws, the cost is high, but the performance and durability are top-notch.

The key to success in these custom micro screws is to choose the screws with moderate cost and also meet quality standards.

Start Your Custom Micro Screw Project with DEK

If you are looking for high-quality and cost-effective custom micro screws which offer precision, you can consider DEK. We offer multiple methods of manufacturing these micro screws– customized according to your specifications and precision.

So, get in touch with us today and specify your application requirements for the custom micro screws.

Conclusion

The significance of custom micro screws in multiple applications plays a vital role. The guide above must have given you an insight into the types of micro screws and manufacturing processes.

Understanding all these details helps you make informed decisions regarding micro screw selection for your applications.

CNC machining is a common process that is done to manufacture components for various industries. It is compatible with almost all types of materials, including ceramics.

If you want to learn about ceramic CNC machining, the guide below can offer you a lot of details. So let's read.

What is Ceramic CNC Machining?

Ceramic CNC machining is a process in which CNC machining tools are used to remove material from the ceramic workpiece.

The removal of the material helps to shape the ceramic components. The machine works with tools that function according to the instructions in the CAD software.

Different types of ceramic materials are opted to create components that have accuracy and tight tolerance for versatile industries.

What are the Properties of Ceramic?

Ceramic is a non-metal material and has various properties that make it suitable for different uses. Some of these properties of ceramics are as follows:

• Ceramics are very hard and, hence, resistant to scratching and wear. Therefore, they are suitable for opting for protective coating, cutting tools, and abrasives.
• Ceramics are brittle, and they can break when subjected to pressure. However, they can withstand certain forces.
• Ceramics have a high melting point, which makes them suitable for applications such as heat shields and furnace linings.
• Ceramics are poor conductors of heat, and hence, they can be opted for applications like engine components and space shuttle tiles. They do not transfer heat easily.
• Ceramics are resistant to attacks of chemicals, oxidation, and even corrosion. Hence, it can be suitable for harsh environments.

CNC Machining Operations for Ceramics

CNC machining operations that are mostly opted for manufacturing ceramic components are discussed below:

CNC Milling

The CNC milling process shapes ceramic components by removing the ceramic material from the workpiece. The cutting tool spins and carves a design on the ceramic workpiece.

This process helps create intricate shapes and consistent cuts. The ceramic components manufactured through this process have a very smooth surface finish.

Core Drilling

Core drilling is also a drilling technique that extracts the material from a piece of ceramic in the form of a cylindrical section. This process helps to drill precise holes and creates a pathway for mounting components or electrical wiring.

CNC machining directs the cutter in a rotating form to create a hole of the exact size and position.

Surface Grinding

Surface grinding uses a grinding wheel to finish the surface of the ceramic component. This process is used to produce components with precision and smooth finishes. Surface grinding is used for ceramic parts that are flat or have parallel surfaces.

Types of Ceramics for CNC Machining

CNC machining is carried out on a wide variety of ceramics, and some of these types are as follows:

Alumina Ceramic

Alumina ceramic is brittle and hard, so it needs slow rates of feed followed by precise tooling.

It is used in manufacturing electrical insulators, wear-resistant components, and implants for the medical field using CNC machining. They are known for their corrosion resistance and tensile strength.

Boron Nitride

Boron nitride is very challenging when it comes to machining, and it can be machined using highly advanced tools. It has excellent insulation and thermal conductivity. Hence, it is used in insulation and semiconductor applications.

Silicon Carbide Ceramic

It is very hard, and when machining it, the need for coolant and diamond tools is significant so that tool wear can be prevented. It is mostly used for manufacturing heat exchangers, bearings, and semiconductor applications. It offers excellent thermal stability and hardness.

Zirconia Ceramic

Zirconia ceramic is tough and can be machined using highly controlled machined environments with diamond tooling. It is used to manufacture oxygen sensors, cutting tools, and dental implants. It offers excellent wear resistance, toughness, and chemical stability.

Steatite Ceramic

It is soft and, hence, easy to machine. It is also known for its affordability and seamless electrical properties. It is used in capacitors, electrical insulations, etc.

Quartz

Quartz is brittle and can easily crack. Therefore, it needs very careful handling during the machining process. It is transparent and has excellent electrical conductivity. It is mostly opted for manufacturing piezoelectric sensors, optical devices, and semiconductor applications.

Cordierite Ceramic

It is very easy to machine and offers excellent thermal shock resistance. It is mostly used in applications like kiln furniture, catalytic converters, and thermal barriers.

Macor

Macor is highly machinable and doesn't need any specialized tools. It offers electrical insulation and is chosen for medical components, vacuum chambers, and electrical components.

Glass

Glass is very sensitive and brittle, so it requires careful machining using diamond tooling. It is known for its transparency and high optical properties. It is used mostly for fiber optics, display screens, and optical lenses.

Graphite

Graphite is very soft, has an excellent lubrication nature, and has thermal conductivity. It is used in manufacturing lubricants, brake linings, electrodes, and crucibles.

Mycalex

It is brittle but can still be machined through carbide tools. The machining parameters should be carefully set. It is used in high-temperature environments as it offers electrical insulation.

Benefits of Ceramic CNC Machining

Ceramic components are CNC machined as they offer excellent benefits when combined with this process. Some of these benefits of ceramic CNC machining are as follows:

• Ceramic CNC machining is a versatile process that can manufacture ceramic components accurately and precisely.
• Ceramic CNC machining is quite cost-effective when compared to other methods like waterjet cutting and laser cutting. It has a high rate of production and lower operation costs.
• CNC machining allows immediate adjustments and hence can cater to the scalability of ceramic CNC machined components.
• Ceramic CNC machining is a precise process and can handle the brittleness of ceramics.
• The process of CNC machining for ceramics helps create components that have complex geometries.
• Ceramic components manufactured using CNC machining have tight tolerance, as required by most applications.

Challenges in Ceramic CNC Machining

Although ceramic CNC machining has various benefits at the same time, it also has some challenges, which are as follows:

• Ceramics are brittle as they have crystalline structures and, hence, are prone to cracking during the process of machining.
• Ceramic materials are at risk when machined as too much pressure may lead to chipping off and cracking the components.
• Some types of ceramics are very hard and cannot be machined using standard tools. They either need highly advanced tools, or they lead to wear and tear of the tools. It ends up increasing the cost of tooling.

Applications of Ceramic CNC Machining

Ceramics are commonly used, and the applications of CNC machining ceramics can be observed in various industries, and some of these are as follows:

Engineering Ceramics

CNC-machined ceramic components are used in engineering ceramics as they can withstand high pressure and temperature. Hence, components like combustion liners, heat exchangers, and turbine parts are manufactured using it.

The process of CNC machining offers precision, and hence, during production, the risk of cracking is also reduced.

Healthcare Sector

Ceramic materials are suitable for medical applications due to their biocompatibility. They can easily be CNC machined and used in joint replacements and implants with the high precision they offer.

Aerospace Industry

The aerospace industry uses CNC machined ceramic components due to their lightweight and intricate nature. The components for aerospace, like heat shields, jet engine nozzles, and turbine blades, are manufactured using it.

CNC machining makes these components precise, and due to their lightweight, they offer fuel efficiency.

Electronics Industry

CNC machining ceramics helps manufacture various components for the electronics industry. The components like semiconductor substrates and circuit boards need high dielectric strength. Hence, the precision CNC machining is used to manufacture these components.

Tips When Designing and CNC Machining Ceramic

When designing and CNC machining ceramic components, some of the tips that ensure effective machining process and optimal results are as follows:

• It is very important to choose the right type of ceramic. Factors like wear resistance, hardness, and thermal stability are important.
• Carbide-based tools and diamond-based tools are the two types of tools that are suitable for CNC machining ceramics. They can handle extreme hardness and hence make the machining process efficient.
• Machining parameters like feed rate, depth of the cut, and cutting speed are very important to manage. They can help reduce wear and ensure optimal performance.
• The use of coolant is significant when machining ceramics as it helps to control the heat and also ensures that the component is free from damage.

Start Your CNC Machining Ceramic Project with DEK

If you are looking forward to having custom ceramic CNC machining components designed and manufactured for your products, you can give us a chance to serve you.

We at DEK sign a nondisclosure agreement to keep your business information and designs confidential.

Moreover, we have an experienced team of engineers with highly advanced CNC machines that provide seamless components.

Conclusion

Ceramic is a very versatile material and has many types. Each type has unique properties. You must have learned everything about ceramic and the CNC machining process of ceramic, which offers you the ability to make informed decisions for your projects.

Molybdenum machining is a challenging task due to the material's nature. It requires specialized processes and different CNC techniques to help achieve the desired results.

If you are willing to learn about the machining process of molybdenum and the important aspects that you must know. Read the guide below.

Understanding Molybdenum Metal

Molybdenum is not very commonly used like steel and aluminum. It is a refractory metal and is a good conductor of electricity. The melting point of molybdenum is 2623° C.

This material also offers high resistance against corrosion and a low coefficient of thermal expansion. It has high strength and can be used in applications that are high-stress.

Techniques in Molybdenum Machining

Molybdenum Machining uses different CNC techniques to achieve the desired details and shapes in the molybdenum components. Some of the techniques adopted for machining molybdenum are as follows:

CNC Milling

CNC milling uses cutting tools that rotate and cut the material from the workpiece. It helps create components that have detailed features and complex geometries. The material molybdenum is hard and hence requires carbide cutting tools for the milling process.

The milling process of molybdenum is carried out at low speed as it helps reduce heat buildup. Moreover, the feed rate must be maintained optimally to help avoid tool wear.

During the process of milling, a coolant is applied so that overheating can be avoided and the tool life is improved.

CNC Turning

CNC turning helps produce components of molybdenum that are cylindrical in shape. The workpiece rotates during the turning process, and the cutting tool stays in its position.

It helps to maintain precise control over the process of cutting, and carbide tools are opted to ensure clean cuts.

During the CNC turning process of molybdenum, the cooling systems are put in place so that heat can be prevented. The tool path and cutting speed are optimized to achieve a smooth surface finish.

CNC Drilling

CNC drilling uses high-speed steel drills, and these drills allow the creation of holes of different depths and sizes. The CNC drilling process helps to drill along multiple axes so that precise holes with intricacy can be achieved.

Challenges in Machining Molybdenum

Molybdenum has impressive properties, but sometimes, the hardness and strength of this material turn out to be challenging for the machinist. Some challenges faced while machining molybdenum are as follows:

Brittleness

Molybdenum offers seamless hardness, and hence, sometimes cutting it could be a challenge. The traditional methods of machining, when used for cutting the molybdenum, make it difficult to achieve clean cuts.

Sometimes, cutting molybdenum could be extremely challenging and lead to tool wear. The brittle nature of molybdenum results in chips being produced, and this causes difficulty in machining.

The problem of brittleness can be resolved by using carbide-made cutting tools that help cut molybdenum effectively. Also, tools with sharp cutting edges help cut neat edges without any chip production.

High Melting Point

Molybdenum has a high melting point, which can favor some applications, but at the same time, machining due to high melting points can be a challenge. Traditional methods of cooling during the process of machining can be insufficient, and the surface finish can be compromised.

In order to deal with the problem of high melting point during machining, coolants that are high performance should be opted for. The water-miscible coolants prove to be helpful to reduce heat.

You can also use a small amount of lubricant, which helps to minimize the coolant consumption, and also choose tools that are made of heat-resistant materials. Such tools are composed of cobalt-based alloys, which stay intact during high temperatures.

Common Grades of Molybdenum Alloy in Machining

Molybdenum has multiple applications and different grades. Each grade has its own properties and suitability for an application. Some of the common grades of machining are as follows:

Pure Molybdenum

Pure molybdenum consists of a very small amount of impurities and a major amount of molybdenum. It has excellent strength and doesn't corrode; it also offers a high melting point.

It is suitable for use in manufacturing furnace components, electrodes for electron beam welding, and crucibles.

TZM Molybdenum Alloy

TZM molybdenum has high strength and toughness. It consists of alloys like tantalum and zirconium. The addition of these two elements ensures to improvement in the creep resistance of molybdenum.

It is suitable for applications involving electrical contacts with high temperatures, engine nozzles for rockets, and gas turbine blades.

Molybdenum-Lanthanum Alloy

Molybdenum-lanthanum alloy helps reduce the wear of machining tools. It also improves the recrystallization of molybdenum and hence is opted for components that need precision. It is opted for aerospace components and semiconductor applications.

Surface Finishes for Machined Molybdenum Parts

Once the process of machining molybdenum is completed, the components may require additional finishing. Some of these options for surface finishing are as follows:

Polishing

The polishing process involves using abrasives, which help to smoothen the molybdenum component surfaces. It also helps to reduce the roughness and improves the finishing of the surface of the parts.

It is suitable for the parts that require high finished gloss and also enhances the functionality of the components.

Sandblasting

Sandblasting uses abrasive particles to blast the surface in order to create a texture to clean it. This process creates uniformity and also removes the contaminants from the surface of molybdenum. This process prepares the surface for further finishing processes.

Passivation

Passivation treats the surface of molybdenum with a solution that has acid, which enhances the corrosion resistance. The process of passivation also removes contaminants and creates a layer of passive oxide.

This layer protects the component from oxidation and even enhances its durability when subjected to a corrosive environment.

Hard Chrome Plating

Hard chrome plating creates a chromium layer on the surface of molybdenum components. This layer gives the component improved hardness and resistance against corrosion and wear. The hard chrome plating makes the surface more durable.

Coating

Coating involves methods like CVD or PVS; the layer of coating improves the protection of the component, adding wear and corrosion resistance. It improves the performance of the components and helps them perform even in harsh environments.

Applications of Molybdenum CNC Machining

Molybdenum machined components are widely used for catering to various industries, and some of the applications of these components are discussed below:

High-Temperature Equipment: Molybdenum is highly suitable for furnace components and heat exchangers as it can withstand extreme heat.

Chemical Processing: It is highly corrosion resistant and hence is chosen for chemical plants to manufacture its fittings, pipes, and valves.

Wear-Resistant Components: Molybdenum is hard and hence is used in crushing machinery, mining equipment and tools for oil drilling.

Semiconductor Manufacturing: The chemical resistance and purity of molybdenum makes it suitable for semiconductor applications.

Gas Turbine Blades: It has high heat resistance, and machined molybdenum components are suitable for jet engines.

Weapon Systems: It offers wear resistance and reliability when chosen for weapon systems.

Start Your CNC Machining Molybdenum Project with DEK

As mentioned above, the molybdenum machining process could be challenging. If you are also looking forward to having services for machining molybdenum for your applications, contact us.

We at DEK ensure high-quality, precise, and affordable molybdenum components. We also sign an NDA with you; you can rest assured about the confidentiality of business information.

Conclusion

The molybdenum machining process has a wide range of applications and properties, which makes it extremely suitable for CNC machining. However, there are some challenges, and those can be managed with efficiency.

CNC machining is a very commonly opted process for manufacturing components used in versatile material applications.

However, investing in CNC machining equipment and training the staff could be an added burden. In order to avoid such investments, many businesses look forward to outsourcing CNC machining.

If you want to know everything about CNC machining outsourcing, you can go through this guide.

What is Precision CNC Machining Outsourcing?

Outsourcing CNC machining is a setup in which you have to collaborate with external CNC machining service providers. They have the machines, trained personnel and expertise to manufacture the components.

The CNC machining components produced have tight tolerance and high precision. By opting to outsource CNC machining processes, you can enjoy cost-efficient components without any in-house investment.

Benefits of CNC Machining Outsourcing

CNC machining outsourcing has ample benefits, some of these benefits are as follows:

Flexibility

CNC machining processes, when outsourced, offer you flexibility. You can always scale your production level to meet your requirements and the market demand. You can adjust the supply of components according to demand.

High Precision

CNC components are highly precise components and it is impossible to achieve this precision with manual methods of manufacturing.

The CNC machining process, when outsourced, allows you to have highly precise components for different applications.

High-Quality Control

Quality is a major consideration in components manufactured through CNC machining. The process itself is automated, and hence, the results are optimal.

However, the service provider also ensures consistency of quality across the entire batch of components.

Small Investment

The profitability of businesses is highly dependent on cost control. When you purchase a CNC machine on your own, you need a high investment.

However, in outsourcing, you pay for the components that you have sourced. Hence, if you are running a small business, you can benefit from outsourcing.

You need not make a high investment, and you can efficiently manage your capital.

Specialized Skills

CNC machining service providers are experts, and they have relevant skills and experience in manufacturing components using CNC machining.

So, when you consider them for having your CNC machined component outsourced, you can be assured of high-quality outcomes.

Minimized Risk

The machining process also comes with the chance of errors, which leads to material wastage.

When you outsource the CNC machining of the components, you can protect yourself from the risk of errors and wastage.

Quick Turnaround Time

Outsourcing CNC machining helps you with quick production. The components are produced quickly, and hence, you can launch your products very quickly.

Challenges of CNC Machining Outsourcing

Outsourcing CNC machining comes with ample benefits, but at the same time, you also have to face some challenges. Some of these challenges are as follows:

Communication Barriers

Maintaining effective coordination and communication with the CNC machining service providers could be challenging.

There might be language barriers, and tracking the schedule of production, quality requirements, and delivery times can be difficult.

Risk of Intellectual Rights

When you outsource CNC machining of your components, you have to share your designs with them, which can be a concern.

Some of the designs might be your own customized designs, which you might wish to keep confidential. In this case agreements must be signed to protect the intellectual property of the company.

Quality Control

When you outsource the manufacturing of CNC components, the manufacturer will have highly advanced equipment, but quality control can still be a challenge.

Before you hand over the CNC machining components project to a supplier, make sure to have an insight into their quality control system.

Risk of Supply Chain

When you rely on a supplier for the CNC machined components, you have to deal with the risk of the supply chain. Various external factors like political issues, weather and other unforeseen circumstances can impact the supply chain.

Costly in Long-Term

The cost of components can be lower in the short run or when you have limited quantities. However, in the long run, the cost of outsourcing can be very high, especially when you have to manufacture a large number of components.

Common Industries Utilizing CNC Machining Outsourcing

Many industries outsource CNC machining to service providers, and some of these industries are as follows:

Aerospace

The aerospace industry requires components which are made using versatile yet durable materials and have high precision. CNC machining ensures that consistency and exact tolerance is achieved.

Hence, aerospace components like engine parts, turbine blades and structural components are usually outsourced.

Automobile Industry

The automobile industry also uses CNC machining and produces versatile components. These components consist of prototypes, engine components and transmission housing.

Automobile companies can maintain a high standard of quality and save on production costs by outsourcing these components.

Medical Industry

The healthcare sector requires a wide range of CNC machined components as accuracy and precision are vital in these applications.

CNC machining allows the production of medical instruments like implants, surgical tools, and medical equipment components. Hence, the medical industry outsources the manufacturing of these components.

Electronics

Electronic components like connectors, enclosures, and heat sinks require a tight tolerance and precise designs, hence they are CNC machined. Electronic manufacturers outsource the process of manufacturing these components to suppliers.

How to Choose the Right Outsourcing CNC Machining Service Partner?

In order to manufacture accurate components, it is very important to choose the right outsourcing service provider. Some of the aspects to consider in this regard are as follows:

• The CNC machining service provider you choose should offer all types of CNC machining services, including CNC turning, CNC drilling, CNC milling, and even EDM. They must also offer surface finishing so that the components are ready for use.
• The track record of the service providers gives an idea of their services and quality. You can always consider checking their past projects and feedback from past clients. It helps you evaluate their reliability.
• CNC machining providers with which you plan to partner should be transparent and accessible. You must be able to communicate with them freely and discuss your requirements; they should also be willing to keep you updated.
• CNC machining service provided to those you plan to outsource the CNC machining projects should be equipped with advanced equipment. The team they have must also possess relevant skills and experience and look for their certifications as well.
• It is very important to choose an outsourcing service for CNC machining that offers value for money. The right service provider will offer you high-quality components with no compromise on the quality, delivery time and precision of the components.

Start Your CNC Machining Outsourcing Project with DEK

If you are looking for the right service provider for your CNC machining project, you can contact us at DEK. We offer high-quality CNC machined components customized to your requirements.

We have a team of experienced professionals who are skilled and dedicated to producing accurate and precise parts. You can rely on us for your projects, as we are even willing to sign an NDA with you to keep your designs and business details confidential.

Conclusion

Outsourcing CNC components comes with ample benefits; you can, as a business, focus on other core areas and get the compensation manufactured for you.

The guide above must have enlightened you with all the essential details on CNC machining outsourcing.

Titanium polishing is important as it enhances the surface finish of titanium components. It helps to remove most of the titanium material from the component to add smoothness.

If you want to learn what is titanium polishing, you can read this guide below.

What is Titanium Polishing?

The process of titanium polishing uses a polishing wax and buffing wheel, which helps reduce the roughness of components. This process enhances the appearance of the titanium component.

Once the component is machined, polishing gives additional coverage and protection to it with a better finish.

Polishing is also a process that allows you to exercise high control; you can, therefore, polish complex and small components of titanium with high precision.

How to Polish Titanium with A Mirror Finish?

The process of polishing titanium with a mirror finish has the following steps:

Cleaning and Degreasing

Titanium manufacturing may leave behind residue and grease on the component, which needs to be cleaned. You can clean it with the help of degreasing agents and then rinse the component well.

Once it is appropriately soaked in water, remove and dry it properly.

Process of Sanding

On the clean and dry titanium component, smoothen the component’s surface with the help of sandpaper. The process of sanding allows the oxidized layer on the surface to be removed. It even improves the metal adhesion for better results after polishing.

Process of Buffing

Buffing gives a mirror-like, shiny appearance to the titanium component. The surface is first cleaned with an alcohol-based cleanser. Once clean, the buffing wheel and metal polish are used to polish, and water is applied to control the heat.

Finishing Stage

After the buffing process, some marks may be left behind on the component. In order to remove these marks, a paint polish is applied on a clean towel, and the surface is rubbed.

A layer of sealant is also applied and left to dry. It achieves the final polished look with a shiny appearance.

Why is Titanium Polishing Important?

There are various reasons that make titanium polishing important, and some of these are as follows:

• The physical appearance of the titanium component is very crucial, along with its performance. Polishing the components enhances the physical look and improves its aesthetics. The surface polishing ensures that the required gloss is achieved on the component.
• The layer of polish on the titanium component enhances its corrosion resistance and wear resistance and even reduces friction.
• Titanium is a poor conductor of electricity. Adding a polished finish allows current to travel through the titanium component, making it conductive.
• The life span of titanium components increases when a layer of polish is added to their surface. It offers corrosion and wear resistance, which makes it durable.

Different Types of Titanium Surface Polishing

Different types of surface polishing options are available for titanium. Some of these are as follows:

Rough Polishing

Rough polishing can be achieved with an abrasive buffing wheel. The wheel has titanium wax polish and silicon oxide and works with minimal force. It is suitable for the round-off corners of components.

Medium Polishing

Medium polishing uses abrasive when made using polish wax and aluminum oxide. Rough polishing leaves behind a dull surface, which can be brightened and smoothed using medium polishing.

Fine Polishing

Fine polishing makes the component of titanium reflective. It uses a wax polish and a soft cotton buffing wheel. It creates a fine surface, and more pressure is exerted on it.

Mirror Polishing

Mirror polishing for titanium components offers a surface finish that looks like a mirror.

The process uses polished wax and a soft buffing wheel, which is made using cotton. This type of buffing wheel is capable of reaching the areas of the component that are difficult to access.

Methods of Polishing Titanium

There are different methods that can be opted for when it comes to polishing titanium, and these are as follows:

Mechanical Polishing

Mechanical polishing is a process in which either machine force or manual force is used to remove material from the surface of titanium. This process helps reduce imperfections on the surface and allows for smoothness.

The process consists of using a combination of coarse and finer grits to remove the material from titanium and achieve a polished finish.

Electropolishing

Electropolishing uses electric current, which creates a chemical reaction leading to polishing the surface. It helps in removing the layer of titanium material and even works well with complex shapes.

The titanium part is submerged in a chemical bath, and the material is removed through anodic dissolution as the current passes.

Chemical Polishing

The process of chemical polishing uses chemical solutions that help in polishing the titanium surface. The titanium part is immersed in a chemical bath, which has acids, and these remove the imperfections of the surface.

It is suitable for the complex and internal areas which are difficult to reach using other methods. It offers a uniform surface finish and is used in medical and aerospace applications.

Plasma Polishing

Plasma polishing is a process in which plasma jets are used. These help to remove the surface material and create a neatly finished surface.

The plasma jet ionizes the titanium and removes the material in a very controlled way. It is suitable for high-precision parts.

Ultrasonic Polishing

Ultrasonic polishing applies ultrasonic vibrations to titanium surfaces. It is a very quick and easy process that leaves behind a seamless finish.

The consistent production of ultrasonic vibration works efficiently regardless of the thrust force.

Tips for Effective Titanium Polishing

Some key tips for effective titanium polishing are as follows:

• Choose the right abrasives for polishing. The coarse grits are opted for the start and then gradually move towards the finer grits.
• Try to use wet sanding so that heat can be reduced and a smooth finish is achieved.
• Do not polish the entire surface in one go. Gradually polish stage by stage to attain optimal outcomes.
• Avoid using coolants as it leads to discoloration of titanium components.

Applications of Polished Titanium Parts

Polished components of titanium cater to various industries, and these are as follows:

Aerospace Sector

Aerospace uses titanium components which are polished as they offer excellent resistance against corrosion. These components are high-strength and lightweight. Engine components of aircraft are manufactured using these parts.

Medical Sector

The medical sector uses titanium polished parts in orthopedic and dental departments. These polished titanium components are used in knee, hip, and dental implants. They offer excellent resistance to chemicals and have high strength.

Automobile Sector

The automobile industry uses titanium polished components in its vehicles as they offer a high strength-to-weight ratio. These components enhance the fuel efficiency of the vehicle, causing it to incur low operating costs.

Moreover, being corrosion resistant, these components are used in exhaust systems of cars as well.

Marine Sector

Titanium is also a commonly adopted material when it comes to marine applications. The polished titanium is marine grade due to its high resistance against corrosion and strength in seawater.

The titanium components can withstand the effects of the environment and hence work well as sea equipment.

Other Surface Finishes Compatible with Titanium Parts

The titanium components, after machining, can be subjected to some other types of surface finishes, too, and these are as follows:

Anodizing

It is an electrochemical process of finishing in which the titanium component is dipped in an electrolyte, and current is passed through it. The process transforms the surface of titanium into titanium oxide, which is durable and resistant to corrosion.

Brushing

This process gives titanium components a bright and flawless surface. The marks of cutting tools and scratches can easily be removed. It enhances the surface using abrasive brushes.

Electroplating

It is a process in which the titanium components get a layer of protection created on the surface. The metals used for adding this layer are tin, nickel, and gold. It improves the corrosion and wear resistance.

Powder Coating

Powder coating is a process of application of dry powder to titanium components. It enhances the aesthetic finish of titanium components.

Conclusion

Titanium polishing enhances the surface of the titanium components in a very commendable way.

If you want to have the titanium components polished for various applications, you can contact us at DEK. We offer different polishing methods and processes at affordable prices and excellent finishing.

FAQs

Can you polish old titanium parts?

Yes, polishing an old titanium part would make it look as good as new.

What is the best buffing compound for titanium?

Green rogue is the best buffing compound for titanium.

How do I choose a buffing wheel for titanium polishing?

When choosing the buffing wheel, look at the ply– the higher the ply, the wider and thicker the buffing wheel will be.

What type of sandpaper works on titanium?

Sandpaper, which is made of silicon carbide of aluminum oxide, is the best for titanium.

What are the common titanium polishing tools and equipment?

The tools and equipment used in titanium polishing are polishing pads, abrasive components for polishing, buffing and cotton polishing wheels, brushes, and sisal.