What is plastic milling?

Plastic milling is a machining technique used to shape and machine plastics through rotary cutting tools called a cutter. This technique falls under the category of machining operations in which material is removed from the workpiece to obtain the desired shape, dimensions and finish. Plastic milling is often performed using CNC (Computer Numerical Control) machines, which allow for precise and automated operations based on digital design drawings.

During plastic milling, the workpiece is clamped on a machine bed and the milling cutter moves at high speed and precision along several axes to remove material. The router can create various geometric shapes, such as slots, cutouts, contours and complex three-dimensional shapes, depending on the design requirements. Plastic milling is suitable for various types of plastics, including acrylic, polycarbonate, ABS, PVC, nylon and more.

The advantages of plastic milling

Plastic milling offers a range of advantages that make it a popular machining technique for shaping and machining plastic materials. Here are the benefits of plastic milling described in detail:

• Accuracy and Precision: Plastic milling uses CNC (Computer Numerical Control) machines that are capable of very precise movements. This allows complex shapes and contours to be created with tight tolerances. The precision of plastic milling is crucial for applications where components must fit perfectly, such as in the medical and aerospace industries.
• Variation in material: Plastic milling is suitable for a wide range of plastics including acrylic, polycarbonate, PVC, ABS, nylon and more. This gives designers the freedom to choose the optimal material to meet the functional and aesthetic requirements of the project.
• Complex designs: Plastic milling makes it possible to create complex geometric shapes that are otherwise difficult to achieve with traditional manufacturing techniques. From detailed cutouts to intricate three-dimensional structures, plastic milling can achieve a wide range of design elements.
• Consistently repeatable: CNC machines provide a high degree of repeatability, meaning that the same operations can be performed over and over again with the same precision. This is vital for producing large numbers of identical parts.
• Reduced lead times: The automated nature of plastic milling results in fast production processes. This is especially valuable when meeting tight deadlines and delivering parts with minimal waiting time.
• Prototype: Plastic milling is excellent for prototyping and testing designs before large-scale production. This makes it possible to make modifications and changes without high cost of making new tools.
• Design freedom: Plastic milling offers designers the freedom to create complex and customized parts according to specific requirements. This opens the door to innovative designs that would otherwise be difficult to achieve.
• Minimal waste: Since plastic milling removes material from the workpiece, there is typically less waste production compared to other manufacturing techniques, such as injection molding.

How does plastic CNC milling work?

Milling is a machining technique in which material is removed from a workpiece using a rotary cutting tool called a cutter. Here is a simple step-by-step guide that explains the basics of milling:

1. Workpiece preparation
Place the workpiece to be machined firmly and accurately on the table of the milling machine. Make sure the workpiece is securely clamped to prevent movement during milling.

2. Tool Selection
Choose the right type of milling tool based on the material being machined and the desired result. There are different types of milling cutters available, such as end mills, face mills and ball mills.

3. Setting Speed and Feed
Set the speed of the milling machine based on the type of material and type of milling tool being used. Also determine the feed rate, or the speed at which the tool moves along the workpiece.

4. Positioning the cutter
Position the cutter at the desired starting point on the workpiece. This is usually done using the CNC control or manual positioning, depending on the type of machine.

5. Start milling
Start the milling machine and the rotary cutting tool begins to remove material from the workpiece. The machine moves the tool along several axes (usually X, Y and Z) to create the desired shape and contour.

6. Performing Operation
The cutting tool cuts through the material as it moves across the workpiece. The cutting motion can vary, such as straight, circular or zigzagging, depending on the desired result and the shape of the workpiece.

7. Cooling and Lubrication
During milling, coolant or cutting fluid is used to reduce the heat generated by friction between the tool and the workpiece. This helps maintain tool life and prevent overheating.

8. Control and Finishing
Monitor machining closely to ensure that the desired shape and dimensions are achieved. Check the workpiece regularly and adjust machine settings if necessary. Once the desired shape is achieved, stop machining.

9. Cleaning and Aftercare
Clean the workpiece and the machine to remove any remaining chips and coolant. The finished workpiece can now be used as planned.

Plastic milling

Batchforce continuously invests in its network, new technologies and innovations to optimize the efficiency and precision of the milling process.

Whether for one-off projects, prototypes or series production, Batchforce strives to provide customers with high-quality plastic parts that meet the highest quality standards. The team of experts is ready to advise and support customers in realizing their specific request.