Category Archives: Acetal

Machining Acetal Shapes

Highly precise acetal parts in a variety of sizes and complexities can be manufactured economically through machining. In the world of Engineering Plastics, Acetal (POM) stock shapes are considered to be some of the easiest to machine. On a scale of 1-10 with 1 being the easiest, many manufacturers place acetal at a 1, compared to a PBI which is often seen as a 10. In fact, machine shops that traditionally make metal parts find they can machine acetal using the same primary tools used for most of the metals they work with. As with any material, there are some good guidelines that can help ensure your success.

Best General Practices for Machining Parts from Acetal (POM) Engineering plastic and Potential Pitfalls of Machining Thermoplastic Shapes

We love engineering plastics! So we are always touting the many benefits of replacing plastics with metals. But this does not mean they are perfect in every way in every situation. There are some differences between plastics and metals that can trip you up when machining. But once you know the potential problems of machining acetal stock shapes machining them can become as easy as the metals machine shops are used to working with now.

Watch out for the heat! As a general rule keep in mind that, due to heat, thermoplastics expansion can be up to 10X greater than metals. Thermoplastics also hold heat longer than metals. Acetal is a thermoplastic material and has a lower thermal conductive aspect than most of the metals it is used to replace. Heat may not be an issue for metals but in the case of an engineering plastic shape from acetal heat build up from machining needs to be monitored and taken into account. Thermoplastics are more elastic than metals. So in general, heat buildup during the machining process can potentially lead to thermal expansion which can distort acetal parts.

If this leaves you concerned about machining plastics, not to worry! Plastics like acetal have numerous benefits that often outweigh the challenges of heat buildup and once you understand how to work with acetal you can easily machine consistently accurate, detailed high quality parts that your customers will be happy with. Be mindful of heat buildup, but also know that acetal does not typically require a coolant (except when drilling or threading). Sawing and machining can usually be set up to minimize heat buildup. (See the table below for Quadrant Engineering Plastics general recommendations for tools and speeds.)

  1. If cooling is used on acetal, compressed air is the standard method. The great thing is this has two benefits. The air cools the part and it keeps chips blown out of the way and keeps the heat built up in the chips off of the part or tools where it can add to any heat buildup. Other options include spray mists and non-aromatic, water soluble coolants.
  2. Sharper tools = Less friction = Less heat. To help reduce heat buildup use extremely sharp cutting tools.
  3. Chipping. Acetal creates chips when being machined so plan for removal of chips as you machine. Removing chips is very important in deep hole drilling. As the chips add to the heat, hole walls can heat to the melting point and clog the drill.
  4. Pieces may be flexible. Make sure the acetal is supported in a way that the material is not distorted, bent, twisted or allowed to deflect away from the tool.
  5. Make sure machining equipment is running as smoothly as possible, reduce any vibration to help aid in accuracy and part quality.
  6. Acetal shapes can be clamped but be aware of how tight.
  7. Choose the right blade for the job. Start by asking yourself what the end product is going to be.
    1. Band saws are good choice for a support groove and for cutting acetal rod and tube. Heat gets dissipated over the long blade.
    2. Circular saws are a good choice for cutting acetal sheet or blocks that have straight edges. Watch the feed speed (most acetal manufacturers have a recommendation).
  8. Choose the right tool for the job too
    1. Opt for positive tool geometries with ground peripheries
    2. For best tool life use carbide tools with ground top surfaces
  9. Is post machining annealing needed? See our previous blog post on this topic.
  10. Choose a machining cycle that will allow for evacuation of the chips from holes and cutting surfaces. For example, when drilling holes choose a cycle that allows drill to ‘peck’ or withdraw at certain points to draw chips back out of the hole.

The following tables are a good starting point for how to set up machining of acetal materials. The information comes two US manufacturers of acetal materials – Quadrant Engineering Plastics and Engineer Plastics provide guidelines for machining the acetal materials they produce. Depending on the manufacturer acetal materials may go through a stress relieving (annealing process) as part of their manufacturing. This helps to ensure the highest possible consistent quality of materials. Testing and consulting with your local tkEP representative on manufacturer recommendations is always a good way to help prevent machining problems. tkEP representatives not only have a broad range of industry experience, many have worked hands on in the industry, and all tkEP representatives attend manufacturer training so we stay on top of current products and how to work them.


As you can see each manufacturer has their own insights into how acetal should be sawn, milled, drilled, or turned. Their are also some pretty broad ranges when it comes to the numbers they provide. This is because these are truly general guidelines that cover the broad range of acetal shapes. Acetal shapes can be acetal homopolymers, acetal copolymer. In addition there are filled acetals and unfilled acetals. Add that to other variations including thickness and size plus environment and it is easy to see that testing for individual applications is necessary.

To read more about acetal plastic shapes check out our online catalog. We have product information as well as a full range of shapes, sizes, and grades of acetal. Read More… For more detailed information on machining from Quadrant EPP and Ensinger Engineering Plastics we’ve included links to pdf files of their machining guides. In these guides you’ll find data for acetals as well as a broad range of other machinable engineering plastics. Last but not least, don’t forget about your friendly local tkEP representative. We are always happy to assist you with finding the right engineered plastics solution for your application. Contact us today 877.246.7700. this one number will put you in contact with your local tkEP branch, or send us a note.

Quadrant Engineering Plastics Machinist Handbook

Ensinger Engineering Plastics Machinist Guide

What’s That Plastic?

Have you ever come across a plastic material, a sheet, rod, or tube, in your shop or warehouse with no label and no way to determine exactly what it is? This can be a difficult challenge due to incredible number of variations that include all the machinable engineering plastics plus all the fillers and additives used to enhance or improve aspects of an engineering plastic’s performance under specific conditions.
However, there are some things you can do to get off to a good start on narrowing down the options.
We’ve put together a handy infographic on some simple do it yourself tests and how the most popular engineering plastics will react to them.

In addition to these methods take a look at our blog post on using the Burn / Flame Test to Identify Plastic Materials


Plastic Materials In Robotic Assisted Surgery

Over the course of the past fifteen years I have concentrated heavily on plastics for the medical device industry and I have been fortunate to have witnessed the incredible advancements that have been, and are still being made in this industry. Robotic assisted surgery is surly one of those advancements.

Advancements in Hip and Knee replacement technologies have grown by leaps and bounds from where they were when I began working with device OEM’s and likewise, polymers have advanced quite rapidly too.  Applications utilizing acetals were slowly surpassed by Polyetherimides and Polyphenylsulfones.  Fifteen years ago PEEK was barely known unless you were involved with the Oil and Gas or Aerospace industries.  Now, PEEK is used as a permanent implant in spinal, shoulder, and other applications.  The rapid advancements of plastics has been side by side with as the technology of surgical procedures has progressed.  Another area of growth for plastics in medical uses is that of certain polymers for both non-implant and implantable surgical procedures and these will continue to evolve as the technology moves ahead at warp speed.

Plastic Materials in Robotic Assisted Surgery

This brings me to Robotic Assisted Surgery.  Fifteen years ago as this type of surgery was being developed with funding from both DARPA and NASA (see below for links to information about these agencies) little was really known about it. I’m sure many of the device manufacturers were aware that one day it would be a reality but I’m not sure how many truly believed that by 2014 it would become as prevalent as it is in todays surgical theater and how much it more it will transcend over the coming years.  Today Robot assisted surgeries have been used in many procedures across many surgical disciplines including joint replacement, open heart surgery, oral surgery and a variety of others. These robot assisted surgeries are more precise than any human can perform and although there is still a surgeon at the controls he or she is performing the surgery from a platform that allows the robot to actually make the movements that were once performed by the surgeons hands. The benefits to the patient are numerous and include less bleeding, greater accuracy, and less invasive just to name a few.  The future of this technology is virtually unlimited.

This image shows a traditional incision (left) vs. a robotic assisted approach (right).

So why am I writing about robotic assisted surgeries in a blog devoted to Engineering Plastics?  Good question.  Because as we move into the next decade I believe we will see more and more polymers used in these robotic platforms.  Maybe the applications of yesterday will be replaced with applications for the polymers of tomorrow.  If a robot can determine that the UHMW implant for a knee arthroplasty is between  25 mm and 35 mm will there be a need to have eight knee provisional trials for that procedure?  Maybe there will only be a need for four or maybe two or maybe none at all. In this day and age of less being more, as in less material waste and less time to production,  robots could be the best new tool in the medical industry. One thing is certain and that is robotic arms will undoubtedly be using high performance plastics to ensure they can withstand the speed and precision ensure they can be deemed reliable for the long-term.  This leads to the issue of preventative maintenance which will also be imperative in maintaining the effectiveness of these units.  As we move forward, it looks as though robotic assisted platforms are here to stay as well as the plastic that is used in these platforms today and on into the future.

Dave Piperi
ThyssenKrupp Materials AIN Plastics Division
Sales and Marketing Manager
Life Sciences

About Dave Piperi 
Dave is the Sales and Marketing Manager for ThyssenKrupp Materials AIN Plastics Division Life Sciences product offering. His focus is on Medical Device, BioPharma and Analytical Equipment markets. Dave has been with AIN Plastics for 15 years and during his time has held several positions including Sales Manager of AIN Plastics New York and Territory Manager.

Related Articles:

Article looks at the difference in incision between robot assisted and traditional surgery methods.

Keep up on all the latest DARPA news on Twitter DARPA on Twitter

See how DARPA is part of developments in medical as well as advanced prosthetics DARPA on YouTube

Read more about DARPA the Robotics Challenge

Visit the NASA website to get the latest news, connect with their blog, and more