CNC Machining Polycarbonate(PC): Tudo o que deve saber
Polycarbonate is a very common material used in applications across various industries. It can be subjected to CNC machining to manufacture various customized parts with high accuracy and precision. Polycarbonate is an easy-to-machine material; however, the process of CNC machining polycarbonate should be understood in detail to achieve the required outcome.
The guide below features an insight into the machining process of polycarbonate, the different grades of polycarbonate and how you can achieve enhanced components. So, let's read below.
A Brief History of CNC Machining Polycarbonate
The process of CNC machining of policarbonato started in the 1950s, and its applications were very limited during that time. As time passed, advances in the technology of CNC machining and improvement in the polycarbonate material led to the enhancement of its machining capability in the 1990s.
However, today, the advanced CNC machines use highly precise tooling, which offers efficiency in the process of polycarbonate machining and is also used in various industries.
Properties of Polycarbonate
Polycarbonate is a versatile plastic comprising excellent properties; each grade of polycarbonate has different properties, and some of these are discussed below:
Resistance Against Impact: Polycarbonates are exceptionally tough and hence offer resistance against impact, which makes them suitable for various high-performance applications.
UV Resistance: There are certain grades of polycarbonate which offer resistance against UV light and can easily be exposed to the sun without any damage.
High Thermal Resistance: Polycarbonates have the capability to withstand high temperatures, which makes them suitable for applications that are subjected to high temperatures, like in the medical sector; repeated sterilization can be well handled by polycarbonates.
Resistance Against Chemical: Polycarbonates offer high resistance to oil, alcohols and various inorganic acids.
Low Shrink Rate: Polycarbonates offer a low shrink rate, which exhibits seamless dimensional stability.
High Optical Clarity: The structure of polycarbonate is amorphous, which makes it transparent; hence, it transmits 90% of the light and can be used instead of glass.
Grades of Polycarbonate
Polycarbonate is a versatile material with multiple grades, and some of these grades of polycarbonate are as follows:
Glass-Filled Polycarbonate
The glass-filled polycarbonate works for the industrial level components and is used as an alternative to metals in various industrial applications. It comprises glass fibers in a range of 10% to 40% and hence adds strength to the standard polycarbonate. It offers toughness and resistance against impact.
General Purpose Polycarbonate
General-purpose polycarbonate consists of high toughness and also is transparent like glass. It has a polished surface and, therefore, is suitable for aesthetic applications. It even offers resistance against UV radiation.
Machine Grade Polycarbonate
Machine-grade polycarbonate offers impact strength, elasticity and high dimensional stability. It also offers seamless electrical conductivity. This grade of polycarbonate is used in applications that require fabrication processes.
TUFFAK® Polycarbonate
It is a very robust grade of polycarbonate which has a strength double that of glass and a very light weight. It works ideally with CNC machining and is even compatible with paints, solvents and adhesives.
AMGARD™ Polycarbonate
It is a very special grade of polycarbonate that is composed of silver ions, and it helps prevent the growth of microorganisms on the surface. It is commonly used in protective shields and medical equipment as the medical industry requires a bacteria-free surface.
Pros and Cons of CNC Machining Polycarbonate
There are various pros of polycarbonate machining, and some of these are as follows:
- The polycarbonate comprises multiple formulations, which include glass-filled and FDA-compliant grades, allowing to find a perfect match for different applications very easily.
- CNC machined polycarbonate consists of a high melting point e low moisture absorption.
- Polycarbonate is suitable for applications like bullet-resistant glass and protective gear because of the high tensile strength it offers.
- The different polycarbonate grades are light in weight and transparent, which helps them emit light effectively.
- Polycarbonate exhibits seamless machining and offers suitable thermal resistance.
There are some limitations associated with machining polycarbonate, which include the following:
- Polycarbonate parts may scratch easily and can be compatible with limited finishing options such as vapor polishing and coating.
- Polycarbonate can deform at high temperatures and sometimes causes poor dimensional accuracy.
- Polycarbonate is abrasive and may cause tool wear during the process of machining which leads to increased cost of tooling.
- Polycarbonate components may turn yellow due to UV light exposure.
- If the components of polycarbonate are large, the process of machining may get complex due to the chance of deformation.
Surface Finishes for CNC Machined Polycarbonate Parts
During the process of CNC machining, polycarbonate may form scratches on the surface and removing them requires some surface finishing processes given below.
Polimento a vapor
The process of vapor polishing offers interior and exterior polishing of the polycarbonate components, which offers a uniform finish. The process of vapor polishing is composed of a solution in which the machined polycarbonate parts are dipped. It is suitable for components of polycarbonate that are equipped with intricate detailing.
Polimento
The process of buffing uses a cotton polishing wheel which spins rapidly and pushes the surface. It is highly efficient and can be used to polish large-sized components with simple features. It doesn't give as clear polishing as vapor polishing but is suitable for less complex components.
Manual Polishing
Manual polishing is a conventional method of polishing that has no tools or equipment incorporated into the process. The surface of the polycarbonate components is rubbed with sandpaper to add uniformity and a clean finish. It is very easy to perform and offers a high gloss on the components.
Applications of Polycarbonate CNC Machining
There are various applications of CNC machined polycarbonate parts, and some of these are as follows:
Automóvel
The CNC-machined polycarbonate components exhibit toughness and impact resistance, which make them suitable for various automobile parts.The transparent and high-impact parts of vehicles, like turning signal lenses, bulletproof windows and headlights, are manufactured using it.
Médico
Polycarbonate components are used in the sector médico in various ways, such as incubators, dialysis machines, and protective gear. Polycarbonate offers heat resistance and dimensional stability and also can withstand sterilization methods involving radiation and autoclaving. Also, the transparency of the polycarbonate components allows doctors to monitor blood infusion conveniently.
Consumer Appliances
Due to the excellent tensile strength, heat resistance and chemical resistance properties, polycarbonate components are used in various consumer appliances. These appliances consist of hair dryers, refrigerators, blenders, electric shavers, food containers, enclosures for television, skylights, fuse boxes and much more.
Conclusão
CNC machining polycarbonate offers components for various applications, and as you have learned from the guide above, the seamless properties of this material make it suitable for multiple applications in a commendable way. The different grades of polycarbonate and essential tips will help you get the CNC polycarbonate components easily.
CNC Machining Polycarbonate at DEK
DEK offers customized CNC-machined polycarbonate components based on your requirements and applications. You can always get in touch with a nossa equipa de vendas and discuss what your expectations are and we will provide you with a relevant customized polycarbonate component that fits in your budget as well as offers your application durability in the longer run.
FAQs
Is Polycarbonate easy to machine?
Yes, polycarbonate is very easy to machine and offers close tolerance without any difficulty while machining.
What are Common Challenges in Polycarbonate Machining?
Polycarbonate is sensitive to some cleaning agents, solvents and chemicals; hence, selecting the right cleaning material and avoiding exposure to harmful chemicals is very important for polycarbonate components.
Is polycarbonate better than acrylic?
Yes, polycarbonate is a very strong material and even stronger than glass, which makes it more resilient than acrylic. It can be used in applications like manufacturing bullet-proof windows.
