Processing Plastics
You can improve your material finish and increase your stock removal with proper tooling. These plastic-specific cutters are preferred over conventional metal-cutting end mills, as they feature sharper edges and larger flute openings to allow for cleaner cuts.
Plastics are typically discussed in 3 basic ways:
Unfilled - virgin plastic with no additives, fillers or reinforcement
Filled - virgin plastic with lubricating additives or strengthening particle fill
Fiber Reinforced - virgin plastic with reinforcing strands of fiber laid in either a random or engineered way
Since the melting point varies greatly from plastic to plastic, the speed (RPM) used should be closely supervised.
Types of Plastic Bits: (modeled after harveytool.com)
Square Bits
Recommended for filled and unfilled plastics, this tool selection of Plastic Cutting End Mills features sharp edges and large flute openings.
Ball Nose Bits
Choose from three distinct styles of ball profile End Mills for Plastics, including Standard 2 flute, long reach 2 flute, and single flute options.
Corner Radius Bits
Ideal for fiber-reinforced applications, these tools feature a corner radius profile and upcut, 2 flute geometry for superior performance.
Finishers Bits
Finishing End Mills for Plastics are engineered with optimized geometries that leave your workpiece with a high-quality, professional finish.
Roughers Bits
Tailored for roughing applications in plastics, our Material Specific End Mills come with irregular edge geometry, enhancing chip control and reducing cutting forces during roughing operations in plastic materials.
Choosing the Right Tool for Your Needs
Selecting the right tool is a crucial decision that can significantly impact the quality and efficiency of your plastic-related projects. Here are some key factors to consider when choosing the correct tool:
Material Compatibility: Different plastics require specific tooling. Consider the type of plastic you are working with, such as acrylic, PVC, HDPE, or polycarbonate, and ensure that the tool you choose is compatible with that material. Tools designed for one plastic may not perform optimally on another.
Tool Type: We offer a wide range of tool types, including router bits, end mills, and cutting blades. The choice of tool type depends on the specific task and the level of precision required. Router bits are excellent for shaping and profiling, while end mills are ideal for more intricate work.
Size and Geometry: Tool size and geometry play a crucial role in the quality of your cuts and the efficiency of your work. Larger tools may be suitable for bulk material removal, while smaller ones are better for fine detailing. Tool geometry, such as upcut or downcut, impacts chip removal and finish quality.
Coatings and Materials: Tool coatings and materials can affect tool life and performance. Our tooling options come with various coatings designed to reduce friction, heat buildup, and extend the life of the tool. Choosing the right coating depends on your specific application.
Machine Compatibility: Ensure that the tool you select is compatible with your machinery, whether you use manual tools, CNC routers, or other equipment. The right tool for your machine ensures safety, precision, and consistency.
Determine Heat Tolerance
The amount of heat generated should always be considered prior to any machining processes, but this is especially the case while working in plastics. While machining plastics, heat must be removed from the contact area between the tool and the workpiece quickly and efficiently to avoid melting and chip welding.
If your plastic has a low melting point, a Single Flute Plastic Cutting End Mill is a good option. This tool has a larger flute valley than its two flute counterpart which allows for bigger chips. With a larger chip, more heat can be transferred away from the material without it melting.
For plastics with a higher heat tolerance, a Two or Three Flute Plastic Cutting End Mill can be utilized. Because it has more cutting edges and allows for higher removal rates, its tool life is extended.
Consider Finish Quality & Deburring
The polymer arrangement in plastics can cause many burrs if the proper tool is not selected. Parts that require hand-deburring offline after the machining process can drain shop resources. A sharp cutting edge is needed to ensure that the plastic is sheared cleanly, reducing the occurrence of burrs. Three Flute Plastic Cutting End Mills can reduce or eliminate the need to hand-deburr a part. These tools employ an improved cutting action and rigidity due to the higher flute count. Their specialized end geometry reduces the circular end marks that are left behind from traditional metal cutting end mills, leaving a cleaner finish with minimal burrs.
Flute Count
Selecting the right flute count for your router and end mill tooling in plastic machining is critical to achieving the desired results. A lower flute count, such as two or three flutes, is ideal for softer plastics and provides excellent chip clearance, reducing heat buildup. In contrast, a higher flute count, like four or more flutes, is better suited for harder plastics, offering increased tool stability and precision. Your choice should consider the specific plastic material, machining speed, and desired finish.