Category Archives: Machining

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

Business Development Team – Adds Value to Buying Through Distribution

TKMNA AIN Plastics Business Development Team Is Dedicated to Providing Solutions to Your Engineered Plastic Needs.

As a Distributor of Engineered Plastics we serve many Industries.  We supply Fabrication Machine Shops as well as OEM Manufacturers.  We work with Design Engineers, Product Developers, Maintenance Specialists, and more. Serving so many industries provides many challenges, so how does AIN Plastics maintain a high level of customer service, satisfaction, good value, and keep up with the thousands of options available in engineered plastics? We have a team. That team includes the Inside and Outside Sales people everyone works with on a day to day basis. We also have 11 branches throughout the US operated by Branch Managers and Fulfillment teams. But we also have an additional team of Industry Segment Managers, (aka Business Development Team) who work across all AIN Plastics locations. This team is comprised of members that between them hold an incomparable amount of knowledge and passion in key industries we serve. Their goal is to assist both the AIN team and our customers by providing knowledgeable support. That support may include training and education, evaluation of applications for material selection and problem solving. In addition the Business Development team uses their depth of Engineered Plastics to find applications that may benefit from an Engineered Plastic solution over traditional materials like metals.

Each Industry Segment Manager focuses on one of the following industries:

  • Oil and Gas / Pump and Valve
  • Power Distribution
  • Medical and Life Sciences
  • Orthotics and Prosthetics (O&P)
  • Transportation

In addition we have an Industry Segment Manager that focuses solely on the high performance DuPont™ Vespel® materials which are often specified by Design Engineers for applications in Aerospace, Plastics Processing, Semiconductor and other highly demanding industries.  By focusing on how we can assist people and educate others in the proper selection and use of engineered plastics we have found we can help customers find ways to improve or enhance applications, reduce costs, and improve efficiency and safety. The AIN Plastics Business Development team all have hands on experience within the plastics industry and in machined parts that provide a base of knowledge they each build on. Because we work with all the major manufacturers of engineered plastic materials, we have the widest selection of products to consider for solutions.  Our Industry Segment Managers also have the opportunity to constantly add training and knowledge to their skills directly from the manufacturers and then share it with customers. We see our job as a distributor as an opportunity to make your job easier and your business successful. In essence we see ourselves as a bridge between customers and suppliers and a partner who brings value.

Meet the Business Development Team

Oil and Gas / Pump and Valve –

Kendall Montague - Business Development Oil and Gas Industry Segment ManagerEmail: Kendall.Montague@thyssenkrupp.com

Phone: 314-502-0813

Kendall Montague is a veteran of the plastics industry with over 15 years of experience. He earned a degree in Economics from Southern Illinois University.  Previous to that Kendall enjoyed a 10 year career as a PGA Club Professional in the greater St. Lous area. After that he transitioned into the plastics industry. Through the IAPD, he has earned the Level 1 and 2 Professional Sales Certifications. Kendall was attracted to AIN Plastics after meeting thyssenkrupp Materials NA, AIN Plastics Division President John Shepherd during a national materials conference.  John’s enthusiasm and vision were shared with Kendall during a team building exercise, and Kendall was left with an impression of the organization that directly aligned with his value-added selling approach. Kendall focuses on working with OEM and MRO Engineers throughout the Oil and Gas industry assisting them with application specifics in thermoplastics material selection. He has also helped develop custom design fabrications that work well with specific CNC equipment. His fabrication experience, a skill learned early in life from his father and developed during his career, is also a valuable tool he brings.  His typical focus applications include bearing, valves, and pump components found in the Oil and Gas markets.

In his spare time Kendall loves being physically active, and especially enjoys biking, running half marathons, and hiking. His passion for running connected him with a fitness group called Road Runners Club of America (www.rrca.org) and he is now one of the over 4,600 members here in the USA, and 16 other countries. Team members can be distinguished by their signature purple camouflage apparel in races and club members range in age from 4 to 85. The group’s only requirement is that, “you have a true desire to maintain and improve your own fitness.” When he’s not participating in half marathons, Kendall enjoys spending time with his childhood sweetheart Jennie whom he met at the age of 13. Home base for Kendall is in the greater St. Louis area but he travels to customers throughout the US to provide hands on support.

Trevor Drake - Business Development - Power Distribution Industry Segment ManagerPower Distribution –

Email: Trevor.Drake@thyssenkrupp.com

Phone: 248-233-5600

Trevor Drake is AIN Plastics Industry Segment Manager for the Power Distribution Industry. Trevor has a well rounded background in business and industry. He is a Canada native who got his start as a plant supervisor in the automotive industry after graduating from the University of Windsor. After completing his MBA in Business Finance, Trevor joined thyssenkrupp Materials NA where he worked as part of the finance team before focusing on Sales and Marketing. Trevor has been with the AIN Plastics Division for over 10 years.

Through his diverse career, Trevor has developed key skills that are of great value.  His vision on Proficiency, the importance of urgency, and his entrepreneurial spirit serve him well. In addition he brings valuable insights from his time in manufacturing plants. Trevor spends his time in the Transportation and Power Generation sectors, focusing on Insulating materials like GPO, Phenolics, Polycarbonates, and other Engineering Plastics.

When Trevor is not working to create solutions for his customers, he enjoys watching his two sons and his daughter develop their talents in sports. He appreciates that he can continue to do what he loves while still enjoying the climate and atmosphere of Canada.

Dave Piperi - Business Development - Medical Life Science Industry Segment ManagerMedical / Life Sciences –

Email: Dave.Piperi@thyssenkrupp.com

Phone: 914-490-1438

Located in the New York, New Jersey area is Industry Segment Manager Dave Piperi.  Dave is an expert in the Life Sciences, Medical, and Analytical Instrumentation Markets.  Dave’s experience in our business is very deep.  Starting as an Inside Salesman gave him a strong education in Engineering Plastics.  Moving to Outside Sales, then Branch Management expanded his experience.  He was particularly interested in AIN Plastics because of its leading role in supplying High Performance Medical Grade Materials.

Dave has assisted customers and led AIN’s growth by developing applications for lab testing equipment used throughout the analytical and bio-pharma areas. Dave supports customers and design engineers by working with them and sorting through the many requirements (including specific industry certifications) and providing engineered plastic solutions. These solutions deliver real world benefits that help improve their products, increase service life and more.

Outside of his work at AIN, Dave enjoys time with his family, watching his son play sports, and relaxing on the beach.

Paul Hanson - Business Development - DuPont Vespel Industry Segment ManagerHigh Performance Materials / DuPont™ Vespel® –

Email: Paul.Hanson@thyssenkrupp.com

Phone: 770-362-9712

For high performance DuPont™ Vespel® Material, Paul Hanson is the go to person. Paul has been working in the Plastics Industry for over 23 years, with experience in the Manufacturing as well as Distribution fields. After earning his Bachelors Degree in Business Finance and his MBA in Business Administration, he moved from Minnesota to Georgia to enter the Plastics Business. Paul has held management positions in Manufacturing and Distribution, as well as Field Sales and Training, Paul has a unique depth of experience in the field.  He was attracted to AIN Plastics because of the company’s long history as a leader in Engineered Plastics.  As an Industry Segment Manager Paul uses his expertise to support the AIN Sales team and their customers in the selection of the right materials for specific applications, often replacing metals and other traditional materials with plastics.  Paul works closely with the DuPont™ Vespel®  organization and brings that experience to our customers, focusing on the Aerospace and Semicon Industries.

Outside of AIN, Paul enjoys spending time with his wife of 32 years, Sara.  They enjoy golfing, traveling, and spending time with their families.  On many weekends you can find him at his brother in law’s drag-strip in Middle Georgia.  His goal is to be racing there soon in a hot Camaro!

Scott Moore - Business Development O&P Industry Segment ManagerOrthotics and Prosthetics –

Email: Scott.Moore@thyssenkrupp.com

Phone: 813-215-8323

Scott Moore is a Florida native who leads our efforts in the Orthotics and Prosthetics Marketplace.  Scott studied Criminal Justice Standards at Polk State College, but soon found his way into the Plastics Industry.  His 20 year career started as an Inside Sales Representative for one of our strategic suppliers, Quadrant Engineering Plastics.  That experience led him to promotions at Quadrant including Inside Sales Manager, Territory Manager, and Team Leader for the Power Transmission Division.

He joined AIN Plastics Business Development Team in 2010 where he focused on DuPont™ Vespel® and Medical Grade Materials. Scott moved back to Florida as the Branch Manager for AIN Plastics Tampa, where he became heavily involved in the growing demand for Orthotics and Prosthetics materials. His materials experience was valuable in rapidly growing our position in this market.

Scott has developed special labeling for our O&P thermoforming products which is of great help to the industry.  He has also expanded our offerings to include adhesives, foams and cork, creating a full market basket. Most recently Scott introduced a unique clear unbreakable material that is ideal for  check / test sockets. As our Industry Segment Manager for O&P, Scott spends his time working in the Field with our Sales team as well as managing the relationships with our National Accounts.  Scott leads our efforts to bring AIN Plastics O&P Materials online as an OPIE Integrated Supplier.

At home, Scott enjoys spending time with Diep, his wife of 14 years, and their two daughters Kayla and Kara. He also finds time to continue his passion for playing the drums, a lifetime enjoyment. He also loves to fish and hunt, and most recently teaching one of his daughters to fish as well.

Thomas Price - Business Development, Transportation Industry Segment ManagerTransportation –

Email: Thomas.Price@thyssenkrupp.com

Phone: 678-230-7944

When it comes to materials for the Transportation Industry, Thomas Price is our resident expert and Industry Manager.  Thomas has over 20 years of Plastics Industry Experience, from Key Account Management to Branch Distribution Management. A graduate of West Virginia institute of Technology,  where he studied Design Engineering, Thomas brings great skills to AIN Plastics.  His primary focus has been on Engineered Plastics used in Aerospace, but also is an expert in Transit and other related Transportation fields.  The newest of the AIN Business Development team, Thomas joined in 2014.  He was attracted to AIN Plastics because of the professionalism displayed by the company, and his familiarity with the transportation industry.  Thomas prides himself on being able to relate to the issues of his customers, as well as the product manufacturers.  He takes an active role in problem solving throughout the supply chain, which makes him a valuable member of our team.

Thomas works out of the Charlotte, North Carolina area, but you can find him most anywhere in North America where Aircraft Interior components are designed, manufactured, and installed.

In his spare time he enjoys being a loving father to his three girls, participating in competitive target shooting, and many other outdoor activities.

In the world of engineered plastics finding the right material can seem like looking for a needle in a hay stack. As an Engineering Plastics Distributor we look to add value not just by carrying the most demanded products, from all of the Major Manufacturers, but also by being experts in the use and selection of these materials.  We can also help you in the Fabrication of these materials into parts … from prototype to full production runs.  Through our Business Development Team and Sales Team we live in the manufacturing plants of America, and we are happy to consult and teach what engineered plastics can do for you. Do you need to reduce noise? Do you need parts that last longer?  Would you like to eliminate the need for lubrication?  If you answered yes, then we can help. As your trusted partner in the distribution supply chain, we look not just at selling a piece of plastic but at providing Engineered Plastics Solutions that help you to get the right plastic material for your application.

 

Scott Petrowski Director of Supply Chain Management ThyssenKrupp Materials NA AIN Plastics DivisionScott Petrowski
Director of Supply Chain Management
ThyssenKrupp Materials NA
AIN Plastics Division

 

Machined Plastic Parts Provide Solutions for Noise Reduction

DSC_0193

The famous line from the 1993 Car-X commercial  “RATTLE RATTLE THUNDER CLATTER BOOM BOOM BOOM”** is a heads up for some people that improvements can be made to reduce noise. For engineers and operators these sounds on a manufacturing line or in a production environment are a trigger for to “investigate” the cause and dig into the field of tribology. In the field of engineered plastics, these noises can also be an opportunity to provide machined parts from thermoplastics as a solution for noise reduction and improved efficiency!

On the floor of production and manufacturing facility environments loud noises are an OSHA concern as they can be an issue for the health and safety of workers. In these situations, parts machined from thermoplastics can provide an design option that can greatly reduce noise levels and improve conditions. In addition, machined plastics can bring about increased efficiencies that reduce downtime.

“As with any occupational hazard, control technology should aim at reducing noise to acceptable levels by action on the work environment. Such action involves the implementation of any measure that will reduce noise being generated, and/or will reduce the noise transmission through the air or through the structure of the workplace. Such measures include modifications of the machinery”

Engineering Noise Control

Professor Colin H. Hansen & Dr Berenice I.F. Goelzer

Department of Mechanical Engineering – World Health Organization

(You can get a .pdf of their complete article on the topic of acoustics here)

Have you considered Thermoplastics, to reduce that noise and improve operational efficiency?

Key Characteristics of Plastic Components:

• Low weight – Easier handling, reduction in drive power required, improved lifting capacity

• Excellent price/performance ratio – Extended part life due to very high wear resistance

• Many are self-lubricating – Maintenance requirements can be reduced or eliminated

• Reduction of equipment noise and vibration

• Mating parts are not worn or damaged

• High mechanical strength, hardness and stiffness

• Impact strength even at low temperatures-cryogenic

• High mechanical dampening capacity

• Excellent fatigue resistance

• Good sliding and emergency running properties

• Outstanding abrasion resistance

• Dimensional stability and weather resistance

• Broad chemical resistance

• Will not corrode

IMG_0465 IMG_0496 UHMW-DSC_0056-2

Here are a few links to some other sources where you can learn more about the use of engineered plastics to help reduce noise and improve efficiency, plus a little link just for fun – in case you have never seen the 1993 commercial.

Connect with Vitrex on LinkedIn to see how a change to machined parts from PEEK helped to reduce noise caused by wind turbines.

Read more about tribology in one of an earlier AIN Plastics blog post by AIN Industry Segment Manager for DuPont™ Vespel® Paul Hanson.

If you don’t know the 1993 commercial we are referring to, no worries, you can find it on YouTube!

ASME (Americann Society of Mechanical Engineers) also has an excellent article that details the benefits many are finding as they replace metal parts with thermoplastic parts.

Finding the right thermoplastic for machined parts is not always a simple straight forward task of looking online or in a catalog. Today’s engineered plastics include thousands of options and many are specially designed with high wear applications in mind like bearing, bushings and more. As a provider of engineered plastic solutions we look to assist you in finding that just right plastic material that will meet the application specific needs and be the best possible value. In the end you may find benefits beyond noise reduction by changing from metal to plastic parts. If you have questions please contact me.

Montague-Sml-DSC_0304

Kendall Montague
Industry Segment Manager

thyssenkrupp Materials NA
AIN Plastics Division

Kendall Montague is a veteran of the plastics industry with 16+ years experience working with OEM and MRO engineers assisting in developing thermoplastics material selection as well as custom design and fabrication using CNC equipment.

Active Member with the Energy & Polymer Group – Houston
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Designing with Thermoplastics in Pump & Valve Components

Why are thermoplastics (engineering plastics) replacing metals and becoming a popular option for machined parts? To answer this question we’ve got a few blog posts that look at different aspects of why people are saying yes to engineering plastics. Pumps and valves have been around for about as long as humans have been constructing things to make life easier. Today pumps and valves occupy places in nearly every industry from medical, laboratory and testing equipment, to oil and gas, agriculture, transportation, buildings and more.

Designing pump and valve components from thermoplastics has the benefit of being made from materials that are corrosion resistant. But, even plastics withstand varying physical elements in different ways so it’s important to understand how plastics can also be affected by the physical elements they will be exposed to. The chart below looks at some of the most common plastic resins and gives a general guideline for how they stand up to potential corrosive elements.

 

Chart of Chemical Resistance for Common Polymer Resins / Thermoplastics

 

CHEMICAL RESISTANCE POLYMER RESINSA Deeper Look at Corrosion and What it Is
Corrosion is the deterioration of a material and its physical properties, Corrosion of a material occurs because of an undesirable reaction with its surrounding environment. In valve applications chemicals may attack the exterior as well as the interior surfaces. As you can see from the chart above both acids and alkalis will attack some materials. Corrosion begins with pitting that is not even visible to the eye. But once it begins corrosion continues to grow and eventually it leads to part failure. But even before creating a leak, pits increase turbulence which affects performance.

Corrosion is caused by more than just hazardous chemicals. As you can see from the chart of common thermoplastics above, sometimes an apparently benign fluid can react, as when sea water flows over brass.

How Can Corrosion of Machined Parts Be Stopped?

The best and most cost-effective way of controlling corrosion is preventing it. Studies have shown that an overall cost savings of 40% can be achieved when corrosion is prevented rather than treated. Prevention entails selecting an engineering plastic that will work best with the media being transported through the device. Whether you are using metals or thermoplastics, all environmental factors should be considered, including cleaning agents and things that might not be thought of as highly corrosive. In some cases a sacrificial layer could be used but these will have a finite life, and as the name implies the sacrificial material needs to be closely monitored and it will still require downtime to apply a new sacrificial layer.

Many customers that replace metal valves and gaskets with engineered plastics often note a number of positive benefits even if the initial part costs more.

  • Reduced maintenance
  • Reduced Downtime 
  • Reduced incidence of part failure
  • Longer lasting parts
  • Overall cost savings
  • Smooth surfaces allow for increased velocity and precision control of flow

Customers with ultra-high purity such as medical device, food processing, or water treatment applications to name a few, require very smooth interior surfaces with absolutely no place for contamination to lurk and with no risk of particles breaking free and joining the fluid. Even microscopic pitting can be cause for parts to be replaced because the pitting can allow for bacteria contamination. Once pitting occurs it is virtually impossible to clean a valve or gasket to the high standards required for high purity applications.

The highly smooth surfaces that can be achieved with machined thermoplastic materials can also reduce turbulence in fluids being transported. This allows for fluids to flow at higher velocities and allows for precision control of pumps.

Beginning with careful material selection, research and talking to experienced plastic professionals can lead to designing pump and valve components that can improve performance and increase life from day-to-day to your most demanding applications.

Do you have questions about material selection for seals and valve gaskets like:

What are the lower cost and lighter weight options to metal-to-metal sealing?

We are having thermal degradation issues with plastics in valve components, can we improve this?

Our seals and gaskets have to withstand higher and higher operating pressure. What  materials have higher compressive capabilities and creep resistance?

These are all questions I am able to assist you with. Feel free to contact me at the information below.

 

 

Montague-Sml-DSC_0304Kendall Montague
Industry Segment Manager

thyssenkrupp Materials NA
AIN Plastics Division

 

Kendall Montague is a veteran of the plastics industry with 16+ years experience working with OEM and MRO engineers assisting in developing thermoplastics material selection as well as custom design and fabrication using CNC equipment.

Active Member with the Energy & Polymer Group – Houston
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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

 

Engineering Plastics use Grows in Food Processing Equipment

iStock_000014977093LargeEngineering Plastics continue to replace metals as key components in food processing equipment. Plastics are often lighter and able to outlast traditional metal parts. A quick look through the variety of plastics available in today’s market shows an increasing number of engineering plastics that are compliant to FDA, USDA, 3A Dairy standards making them available in applications where they will come into direct contact with food. They are also being chosen for their
ability to create a quieter work environment.

With 2014 looking to be a great year for Food Processing equipment sales I wanted to share what we most find in food processing applications and why.

UHMW
UHMW continues to lead the way (by pounds sold in the United States) in the transformation from metal to plastic parts.  For more information on materials sold in the U.S. see this article by the American Chemical Council. Compared to steel UHMW is just 1/7th the weight. In addition UHMW is corrosion resistant. UHMW is a great option for room temperature applications like guides, paddles, and cutting surfaces.  Recent advances include the introduction of metal detectable versions that can be recognized by your detection systems in line.

Nylons
For bearing and wear applications, Nylon materials have been the workhorse for over 30 years.  Like UHMW, Nylon is also light weight, and provides lubrication – free operation making it a great material for producing bearings or bushings.  Gears and sprockets made of Nylon have been popular because they can reduce noise in work areas. They can also improve the efficiency of production lines conveying food and liquids in your plants by lasting longer than metals, which reduces downtime, and by allowing lines to run faster.

Acetals
For many components, Acetal is the best choice for metal replacement, and we find its popularity is growing quickly in the food processing industry.  Acetal (Delrin Homopolymer or CoPolymer brands like Acetron GP and Celcon) are very easy to machine, and their very low moisture absorption rates make them a good choice for the often wet environment of food processing.  Acetals are harder than Nylons and maintain dimensional stability where Nylons tend to be more flexible. In many applications Acetals can handle continuous use temperatures up to 210° F and they are typically compatible with most cleaning solutions, a huge plus in the food processing industry.

ERTALYTE®
A popular speciality material is Quadrant Engineering Plastics Ertalyte material.  Ertalyte has unique properties that allow it to wear like Acetal in wet environments and like Nylon in dry or unlubricated environments.  I like to think of it as giving you the best of both worlds! Ertalyte also is highly resistant to stains generated by things like tomato based sauces and green vegetables.  Ertalyte also has high dimensional stability that meets the demands of the highly precise machining tolerances required in filling pistons and fluid manifolds.

In looking to the future of food processing the demands are heavy. Companies are working hard to keep consumer prices in line while still making a profit. Food processing companies are achieving these goals by improving efficiency and creating better work environments. Plastics are an increasingly big part of the solution because their use in parts can improve line speeds, decrease maintenance downtime, and even make for a quieter work environment.

As I look at the Engineering Plastics and High Performance Materials we have here at AIN Plastics I’m pleased to see how they are being used to improve the food processing industry and I’m excited to see the new applications our customers are working on as well as the new materials our suppliers are always working on. If you have an application you’ve been scratching your head over, give us a call. We know there are lots of options and we can help you take some of the guess work out of finding out if Engineering Plastics are right for your application.

Paul Hanson

Sales and Marketing Manager
DuPont Vespel®
ThyssenKrupp Materials NA
AIN Plastics Division

email: paul.hanson@thyssenkrupp.com

For more information on Engineering Plastics visit http://www.tkmna.com/tkmna/Products/Plastics/Engineering/index.html

Machined or Molded Plastic Parts – What Are the Differences?

A plastic part by any other name would still be a plastic part, wouldn’t it? Yes it would. But the way those plastic parts produced; either by molding plastic parts or by machining plastic parts are dramatically different. Those differences in the process of making plastic parts can result in big differences in lead times, cost, and quality. Below are things to consider when looking at how to manufacture plastic parts and some answers that may help you to decide.

How Many Plastic Parts do you Need to Make?

MOLDED: Molded Plastic parts have been around since the first machine for the process was patented in 1872 by John Wesley Hyatt and his brother Isaiah so its easy to see how this became one of the standard processes for creating plastic parts. Mold machines are used to run mass produced plastic parts from tooth brushes to auto parts and everything in-between. Creation of the mold(s) costs thousands of dollars, requires time up front to make the mold(s) and the molds require maintenance over their life and storage when not in use.

MACHINED: Depending on the project, volumes from 25 to 5,000 parts can often be machined more cost effectively than molded. For small parts, you may have a lower final cost by using high performance screw machines that can run circles around expensive multi-cavity molds. This means shorter lead times than molded parts and little up front cost. Machined parts don’t require secondary machining to clean a part once it is ejected from the mold.

Will You Need to Make Changes to Your Part Design?

MOLDED: Parts made from molds require that the mold be made first which is more time and expense up front. In addition a mold will require maintenance over it’s service life and storage space when it isn’t in use. Changes to a mold are costly in terms of time and dollars to either change or make a new mold, depending on the changes needed.

MACHINED: Machined parts allow for shorter lead times and flexibility in making design changes because they are run directly from a CAD file. Overall, machining can be used to create very complex parts including parts with undercuts and thick walls and the materials are more homogenous across the length and width of the part.

How Important Are Tight Tolerances and Dimensional Stability?

MOLDED: Every plastic behaves differently. But in general plastic parts made from molds may not be as dimensionally stable as machined parts. There is more chance the parts will not be as homogeneous across the length and width of a part. The molding process is not ideal for large parts or where there are thick walls. Tolerances of +/- .005″ are typically the best that can be achieved in molded parts. This compares to +/- .001″ for machined parts.

MACHINED: Many of today’s high performance engineering plastics, such as DuPont Vespel, PEEK, PBI or others can take extreme temperatures of 250 or even 450 degrees and remain dimensionally stable. Many of these materials are also chemical resistant. Additionally machined parts have less internal stress and tolerances of +/- .001″ or better can be achieved.

How Large or Complex Are Your Parts?

MOLDED: Small to mid-size plastic parts can work well. Large volumes can be run fast. But large plastic parts with thick walls, or complicated undercuts can be an issue for mold design. Materials cooling at different  temperatures within a mold can result in more internal stress and a less homogeneous material. Undercuts can pose a mold design challenge with how to release the part from the mold. Plastic parts fresh from the mold may require secondary machining to remove flash, parting lines, or ejector marks, adding to production time and cost.

MACHINED: Large parts and parts with complicated undercuts can be made quickly and efficiently by machining processes. Thick cross sections will have higher, more consistent mechanical properties. Again, because there is no mold to be made, the up front investment and lead time is much shorter. Machining also handles threading extremely well and machined parts will have no parting line, ejector marks, or flash. The availability and selection of engineering plastics means many prototypes can be made in production-equivalent materials. Plastics are more often being found to be a good alternative to metals. They can often be machined on the same equipment and many high temperature engineering plastics offer features such as lightweight, flexibility, high strength, resistance to corrosion, excellent durability, high heat tolerance and chemical resistance. Some plastics, such as those for bearings even require little or no lubrication making them even more cost effective on the service end.

The moral of this blog – a plastic part by any other name is still a plastic part but how you get to create that part could make all the difference in the world. Molded plastic parts have their place, but before going down the path of investing in molds it may be worth a little time considering the questions in this blog and determining if molded or machined is the best option.

 

See you in the blogosphere again soon!

Lisa Anderson

Marketing Manager
ThyssenKrupp Materials, NA
AIN Plastics Division

www.tkmna.com

AIN Plastics Expands – New Branch in St. Louis, MO

After a year or more of research and hard work to expand, AIN Plastics is pleased to announce the opening of a new AIN Plastics Distributor Branch in the St. Louis Missouri area.

New Business Locations Don’t Happen Overnight

This week I had the opportunity to talk with Chris Urban, Branch Manager for AIN Plastics new St. Louis Area Distribution Facility. I asked him what it took to get a new branch opened up. Chris said they started with finding the right location, which turned out to be in the same building as the St. Louis area ThyssenKrupp Materials NA Facility (AIN Plastics parent company since 1993). Then came finding the right equipment which includes a brand new saw for custom cutting orders and finding just the right people with both customer service and previous plastics experience. Chris noted they wanted to hit the ground running from their first day of business. He went on to say:

“We have worked hard in preparation over the past year prior to our opening and we are very excited to see our hard work pay off. ThyssenKrupp Materials NA, AIN Plastics Division did a great deal of research regarding this project. St. Louis is an ideal location to further extend our distribution. From this branch we will be able to provide customer service and quick turn around on orders to Missouri and surrounding states.”

Chris also said he wanted to thank all the AIN people that came to St. Louis from other branches to support his team for the first few days. “Having the support of the entire AIN Plastics company has made starting the new branch a great experience for everyone. We feel truly supported and connected to everyone in the company.”

AIN Offers More than Materials – It’s about Value Added Services

I asked Chris about the services they will be offering. Chris says the new AIN Plastics distribution branch offers a comprehensive list of value added services including:

  • Close tolerance custom cutting of orders
  • Customized Inventory and stocking programs including just in time delivery solutions
  • A vast inventory of sheet and rod materials, some of them highly specialized
  • Professional team with years of plastics industry experience
  • ThyssenKrupp Nationwide Logistics for the best possible delivery

More Manufacturers are Choosing Plastic Due to it’s Many Benefits

Chris talked about how the selection of plastics is changing rapidly due to its value as a lightweight component in manufacturing, it’s ability to be reused and recycled, and it’s cost. Plastics are often an affordable material compared to more traditional resources such as metal, wood, or glass, and they often outlast and outperform those materials. Researchers are always developing even better plastics. “We have a team in place that can help customers sort through and not just find a plastic that will work, but rather the right plastic for their application.”

GPO, Materials for O&P, TeflonPlastics, Plastics, and More!

When it comes to what plastics the St. Louis AIN Plastics branch will stock, Chris gave me a short rundown and said this doesn’t come close to covering all the materials we have:

  • Industrial Plastics
  • High Pressure Laminates
  • Engineering Plastics including
    • ABS
    • Acetal
    • Cast Acrylic
    • Polycarbonate
    • Radel R
    • Semitron
    • Techtron
  • Composite Tooling products
    • RAMPF Styling, Modeling, and Tooling Boards
    • RAMPF Close Contour Paste and Casting Materials
    • Thermoform Materials
    • Epoxy Casting and Laminating Resins
    • Foundry and Pattern Materials
  • Plastic Tubing including Medical and Food Grade
  • FDA compliant plastics for medical and food service industries
  • Silicone
  • Rapid Prototyping
  • DuPont TM Vespel® (AIN Plastics is the Authorized Distributor)

Well, you get the idea, it’s a long list and that’s just the beginning. Chris says the best way to learn more is by visiting the website ainplastics.com or better yet by giving them a call at 877.246.7700.
The AIN Plastics Distribution Facility is located next to the ThyssenKrupp Materials NA facility:

59 Interstate Drive
Wentzville, MO 63385

Hours of operation are Monday – Friday 8:00 AM – 5:00 PM.

For more information regarding the new AIN Plastics St. Louis Area Branch

CONTACT: Christopher Urban

TEL: 877.246.7700

DIRECT: 636-698-6295

FAX: 636-327-4369

EMAIL: christopher.urban@thyssenkrupp.com

That’s it for this week’s news. Look for our other posts where we look not at ourselves, but at the world of plastics. What’s new, what works, why certain plastics are good in specific applications and more. IF you do want to learn more about AIN Plastics and our history check out the “About Us” page on our site.

See you in the blogosphere again soon!

Lisa Anderson

Marketing Manager
ThyssenKrupp Materials, NA
AIN Plastics Division

www.ainplastics.com

 

New Video – How to Machine DuPont™ Vespel®

Avoid Costly Machining Mistakes!

AIN Plastics new video based version of the DuPont™ Vespel® Machining Guide For Vespel Polyimide Parts is now available for viewing! Just a few minutes of your time can give you helpful tips and tricks so you successfully machine DuPont™ Vespel® parts each and every time.

DuPont™ Vespel® is an investment in high quality polyimide material so you want to be sure you know all the ins and outs of working with it. This informative video is designed to help you obtain the best possible results when machining parts from authentic DuPont™ Vespel® stock shapes. In a few minutes this video will take you through all the basics from what tools to use, to machining techniques, to finishing and polishing your DuPont™ Vespel® parts.

Please click the link below to view the new video right now…

http://www.youtube.com/watch?v=Ll5MGUzEkI8

ABOUT AIN Plastics and DuPont™ Vespel®… 

The AIN Plastics Division of ThyssenKrupp Materials NA is the exclusive distributor of authentic DuPont™ Vespel® shapes in the Eastern United States and Canada.  As such, we stock an extensive inventory of authentic Vespel® shapes including rod, bar and disks manufactured in the proprietary DuPont™ isostatic molding process.  We also stock all grades of Vespel® plaque and can provide our customers with custom gauges and cut-to-size blanks.  AIN Plastics also stocks Vespel® balls in a variety of diameters and can offer custom sizes upon request.

 

Companion Guide to the video Available for Download:

Get all the details of machining DuPont™ Vespel® including drawings of how to customize drill bits, informational table on feed speeds and more in the downloadable print guide.

Click here.

 

 

For more information or questions about how to work with DuPont™ Vespel® please feel free to contact me directly.

Shawn Lynam

ThyssenKrupp Materials, AIN Plastics Division
Director of Business Development

shawn.lynam@thyssenkrupp.com

ph: 412.352.2789

www.ainplastics.com

More DuPont™ Vespel® Literature Available for download:

DuPont Vespel® Motion Solutions

DuPont Vespel® Motion Solutions

DuPont Vespel® SCP Parts

DuPont Vespel® SCP Parts

Insulator Solutions

DuPont Vespel® Insulator Solutions

DuPont Vespel® Sealing Solutions

DuPont Vespel® Sealing Solutions

 

Join me for an introduction to the world of plastics!

Your Guide to Plastics Past, Present, and Future…

Lisa Anderson, Marketing Manager ThyssenKrupp Materials NA, AIN Plastics Division

It’s hard to believe it’s been over 6 months since I began working at AIN Plastics. Hard to believe because everyday is packed full of lots of projects and lots of things to learn about plastics. There have been new people to meet and old friends to reconnect with, and it’s all been really fun, so the time has truly flown by.

As I’ve gone through these months I developed a hunch. My guess is, when it come to plastics for manufacturing and specialty uses, a lot of you in many industries are in the same boat because there are so many material choices out there. So I’m inviting you to take the journey along with me to learn about plastics. What are plastics, what are the different types, why are they being used more and more, and what plastics will work for your applications. In fact, I hope you’ll share your applications and experiences as well.

While we are at it we’ll take a stroll through plastics history too. I’m a huge history buff so every time I hear about a plastic I like to dig in and find out how it all started. These days plastics seem to surround us, but it wasn’t that long ago we relied on other materials such as wood, metal, and glass for everything from IV ‘bottles’, to baby bottles, cooking utensils, sporting equipment. Hmmm – what were shower curtains before plastic? I’ll get back to you on that one, or if you know, please share! We love comments.

So let’s get started! Today I’d like to stay in the present and take a look at a helpful piece that came across my desk. As we all know there are literally thousands of types of plastic materials out there and more are hitting the market all the time, so anytime there is something that can help you to select the best one for the job we here at AIN will be sure to share it with you. After all, getting the right material helps everyone. The item that came across my desk is in regards to Materials for seals and gaskets.

So let’s start with a couple of questions –  
• Do you make seals or gaskets?
• Do you need your seals and gaskets to be Teflon®?
• Do you have a high temperature application?
• Do you need FDA compliant seal and gasket material?

The most common choices for seals and gaskets are UHMW – PE, Teflon, and PEEK. These are all great options, but another material called Fluorosint® has, until now been a little less known for seals and gaskets however, it is proving to give material specifiers another excellent option for certain higher temperature applications. Two Fluorosint® materials are FDA compliant giving you options for special applications in food or medical applications.

In selecting material for gaskets and seals temperature and pressure are the two biggest factors people generally consider. This chart easily shows where TIVAR® UHMW-PE, Teflon®, Ketron® PEEK, filled and unfilled PTFE, and Fluorosint® and Duratron® fit in as material options. Test results clearly show that Fluorosint® and Duratron® fit very well into a gap left for high temperature and high pressure applications. To make your selection even more exact, Quadrant (manufacturer of Fluorosint®) has developed several Fluorosint® materials (207, HPV, 500) and each was specifically developed with a certain application area in mind.

Below is a Material Selector Guide that covers all of these materials in two easy formats. One simply compares how a product does in relation to heat and pressure. The other compares Fluorosint® to Rulon®, another common material for seals and gaskets. You can also compare the FDA compliant materials.

Material Selector Guide for PTFE Seal and Gasket Material

From materials suitable for average heat and pressure to the highest, this chart will help you to easily cross reference common seal and gasket materials.

 

Chart comparing Rulon to Flurosint

Compare test results of Fluorosint and Rulon and see at a glance what material fits your application.

As we go forward I’ll be looking at each of these products on an individual basis. But, if you see something here you like and you want to know all the details right now, we do have more information available on our website: Fluorosint Product Information. You can also talk to one of people. We have a knowledgeable staff that can help with any questions you may have about seal and gasket materials. Just call 877.246.7700 and you will be connected with the AIN Plastics office nearest you.

If you are along for the journey that’s great!  If seals and gaskets aren’t your thing, no worries, I’ll be talking about all sorts of other materials as we go. In fact, you can sign up and get our posts in your mailbox so you don’t miss the latest.

I hope you find these charts helpful in your search for that just right seal or gasket material. We’ll see you in the blogosphere again very soon!

Lisa Anderson

Marketing Manager
ThyssenKrupp Materials, NA
AIN Plastics Division