Plastic Machining - AIP Precision Machining

Top 5 Things to Look for When Choosing an Aerospace Plastics Manufacturer

December 18, 2017

When looking to design a custom critical component for the aerospace industry, finding the right plastics manufacturer is just as important as deciding what resin works best for your project’s needs. The use of high performing plastics and thermoplastics such as ULTEM, TORLON, PEEK, and RADEL has quadrupled in aerospace design over the last 45 years thanks to their unique dynamic properties, and with them comes the need for precise machining and manufacturing.

Here are 5 considerations you should take into account before choosing your aerospace plastic parts manufacturing company:

Capabilities & Competency

Before hiring a plastics manufacturing company, first ensure that they have the plastic designing and production capabilities necessary to handle your aerospace project’s needs. The three main plastic production processes are 3D Printing, Injection Molding and Plastics Machining. Discovering which technology is most appropriate for your project is dependent on your project’s requirements… and the plastics manufacturer you decide on should be able to tell you the pros and cons of each technology.

The manufacturer you choose should also have the ability to navigate from your product’s initial vision through its production, addressing quality and customer care every step of the way. They should be able to competently handle the raw plastic materials of your choice as well, so that you receive the highest quality product in regards to cost, time, precision, efficiency, materials and more. Your project, regardless of specificity, can be machined into a highly precise and extremely resilient product.

Here at AIP Precision Machining, our decades of experience working with ULTEM, TORLON, PEEK, and RADEL high performing plastics ensures smooth navigation from your project’s start to finish.

Industry Standards

Product manufacturing companies must follow industry standards like International Organization for Standardization (ISO), Food and Drug Administration (FDA), International Traffic in Arms Regulation (ITAR) and more in order to ensure that their products hold up to specific requirements. Be wary of companies that have a default “Standard” methods—these are made-up specifications that do not follow recognized, insured specifications.

Take a careful look at a company’s ISO certifications. For instance, ISO 9001 is focused on meeting customer expectations, continually delivering customer satisfaction and it requires an organization to demonstrate constant improvement… If an organization doesn’t have this regulated license, you may want to ask them why.

Also, consider other notable ISO certifications like the AS9100 standard which is similar to the ISO 9001 standard, but with additional requirements for aerospace manufacturing that are tailored to a particular industry’s quality system expectations and regulatory requirements.

Here at AIP Precision Machining, not only are we registered to these standards, but we are registered to the most recent version of the ISO standards.

Additional Services

Plenty of plastic manufacturing firms offer consulting services as well as developmental processes. Going with a plastic product manufacturing company that has manufacturing conceptualization engineers can help in the long run if your project requires any design modifications. Engineering support also ensures efficiency through every step of your project’s progression.

Some plastics manufacturers also offer quality assurance measures. Not every company guarantees that their end products will hold up to your specifications but the firms that do will additionally offer services focused on comprehensive product design, development, patent registration guidance and prototype creation.

Here at AIP Precision Machining, we’re proud to offer a complete and effective quality assurance process that focuses on product quality, fast delivery, and cost-effective options.

Domestic vs. Overseas

If you decide to use an overseas factory, asking the right questions is critical to determine if they have the capabilities, credentials, and experience to become your trusted partner. It can often be difficult to find a reliable company that delivers high quality work. Some ways to find the best plastic manufacturer overseas is by asking for referrals, actually flying to their location, and asking a lot of questions and paying close attention to their responses. Many overseas factories will usually have a U.S.-based agent to represent them. If you find a company that seems like a good fit, ask to contact their domestic agent.

Domestic manufacturers, meanwhile, greatly reduce delivery times and shipping expenses; one who is in your same time zone allows for easy communication and improved customer services. There’s also the advantage that U.S. manufacturers have higher quality and labor standards, greater payment security, and high intellectual property right protection.

AIP Precision Machining is headquartered in Daytona Beach, Florida with an additional sales office in southern California. We provide an “open door” policy to our facility for potential and existing clients.

Experience & Expertise

Checking the track record of a company is important to get a clear outline of their performance, customer satisfaction, and overall product deliverability. Ask about their work history to see their range of experience and their level of expertise with aerospace projects similar to yours.

For instance, we at AIP Precision Machining have worked with leading aerospace and defense engineers and contractors such as Lockheed Martin, BAE Systems, and GE Aviation. With our 35+ years of polymer machining experience, we’re ready to take on the most stringent challenge to meet your needs.

If you’re interested in learning more about how to choose a plastic product manufacturer for your critical aerospace components, feel free to reach out to us online or call us at +1 386.274.5335 for a free consultation with one of our highly-skilled engineers.

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Settling the Debate: 3D Printing, Injection Molding or Plastic Machining

July 27, 2017

To a certain degree, 3D printing, injection molding, and plastic machining technology overlap in their capabilities and offerings. But which fabrication process is most appropriate for your project? What are their key differentiators? The following article assesses the utility of each technology with regard to precision, efficiency, materials and more.

Capabilities

3D printing is an additive manufacturing process that prints layers of plastic substance in three dimensions onto a single point. The popularity of 3D has grown significantly over the past few years, and it can easily be used for rapid prototyping, DIY production and manufacturing by small-scale engineers or designers. Many of the advances in 3D printing have been focused on bringing down prices, rather than technological advancement so that it can be more accessible to “mom-and-pop” users who are otherwise not eligible for the more expensive and advanced manufacturing processes.

Another additive technology, injection molding is a manufacturing process in which parts are produced by injecting materials in liquid form into a mold. Commonly performed with thermoplastic polymers, it can be used with a variety of other metal and glass materials. Small pellets of material are heated into a molten liquid which is then injected into a mold at high pressures and rapidly cooled—causing it to harden—and then ejected from the mold, exposing the part to air. Two of its key benefits include a fully automated process—permitting very high rates of production—and also that its molds allow for highly detailed and intricate parts.

Finally, plastic machining, or CNC (Computer Numerical Control) plastic machining or CNC milling, involves the precise removal of layers from a material. Typically beginning with a block of the desired plastic material, plastic machining involves removing material layers at a time and allows for many different materials to be used. Introduced by MIT during the 1950s, this technique utilizing drilling tools to carve plastics—and because it’s computer-controlled, extremely precise and tolerant products are achieved.

Comparing the Options

	3D Printing	Injection Molding	Plastic Machining
Cost	Very low cost when you need 1-10 rapid design iterations on a prototype part.	Because creating (or updating) a mold can end up being much more expensive than the actual order itself, this is only cost-effective with very large-scale projects.	Significantly cost-effective when you need a few parts up to a few thousand.
Design	Designs can be highly personalized and unique—this technology is often used by artists and creative professionals.	Allows for deep features, square holes and living hinges to be produced easily.	High design flexibility at lower costs are allowed.
Material	Very limited in comparison to other plastic fabrication and unable to achieve the same smooth surfaces as the other technologies.	Injection molding has a much wider range of materials available for use compared to 3D printing but is more limited than CNC machining.	Broadest range of materials are allowed—CNC plastic machining also achieves the smoothest finish with the fewest imperfections.
Production	Fast and extremely convenient—small products can be machined in seconds.	Requires time to make the mold but once the mold is finalized, production moves quickly.	One of the fastest forms of fabrication and can easily scale between small and large outputs.
Tolerance	3D printed prototypes are not typically finished parts and are much more likely to delaminate. Best for home and personal consumer-grade products.	Parts are molded at tighter tolerances than 3D printed parts but are not as tolerant as plastic machined parts.	Highest tolerances available—parts are able to reach +/- 0.002 mm and are best for demanding industries like aerospace and defense, medical and life sciences and power generation.

Why Plastics Machining Ranks Best

From the above chart, you can see the differentiators of each fabrication process. However, we’ve found that CNC plastic machining is by far the most precise and beneficial process for custom applications.

Cost-wise, plastics machining is the most effective for any project that requires unique, strong designs. 3D printing is the cheapest form of fabrication but you get what you pay for with that medium… and the quality typically just isn’t there. Injection molding, meanwhile, offers much stronger products than those that are 3D printed, but modifications to a mold are extremely expensive and injection molded products are not as tolerant as plastic machined parts.

Looking at design abilities, each medium offers a wide range of capabilities but again, if it’s quality that your project needs, CNC machining is the way to go—3D printed materials are really only suited to personal or home use and injection molded products cannot hold up to the rigors of the aerospace and defense, medical or power and energy industries (among others). Further, machining designs are crafted on the same computer applications that 3D printing uses so there’s no cost associated with changing the design of the product (unlike injection molding, where a new mold would then need to be created).

It is important to note that CNC plastic machining is a specialized craft… not just anyone interested in 3D modeling can create the design for a plastic machined product. Here at AIP Precision Machining, we have over 35 years of technical design expertise and we work diligently with our clients to craft products that exactly meet their project requirements.

If you’re looking to decide on a fabrication process via the material selection available to you, plastics machining offers the widest range of diverse thermoplastics for your project. 3D printing has not advanced its material range in many years and because injection molding requires liquidating its materials, you won’t be able to use the stronger, heat-resistant plastics that might be best for your needs. CNC machining is the only process that allows you to choose from the full assortment of material selections.

3D printing and CNC machining tie for the fastest production times, as both take minutes to complete. Injection molding, however, requires more time to make the mold (which can take weeks to finalize).

Finally, if your project requires the highest levels of tolerance, precision machining produces the most precise and extremely tolerant products. It’s the only fabrication process suited for critical pieces.

Want More Information?

Of 3D printing, injection molding and CNC plastic machining, one process is not necessarily better than the other—it’s dependent on your project requirements. However, plastics machining is by far the most specialized and precise option for high-quality, critical parts needed in industries like aerospace and defense, medical and life sciences and power and energy.

Here at AIP Precision Machining, we commonly craft pieces that are able to survive the rigors of space, the inside of a human body or the corrosive chemicals used on an oil rig. We offer state-of-the-art technology and extensive expertise to provide you with the highest quality products. Contact us to learn more about our process and what CNC plastics machining could do for you.

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Getting Kids Interested in Plastics Manufacturing

July 6, 2017

Kids are hard at work in their plastics manufacturing summer camp.

The word “summer camp” denotes images of canoeing on a lake, staying up late to tell ghost stories or hiking through the woods. But today, that term is expanding to include hardwiring electronics, designing products through CAD and making plastic products kids can take home… Huh?

The plastics manufacturing industry has begun partnering with career centers, schools and summer camps in an attempt to bring attention to manufacturing careers. Camps designed for fifth through twelfth graders are popping up that allow kids to design, build and manufacture plastic projects, giving them an idea of what a job in the plastics industry might be like.

Plastics, like other production sectors, is experiencing a shortage of skilled workers: with only seasoned veterans getting ready to retire and newbies fresh out of school, the generation in-between was steered away from manufacturing jobs by teachers and parents who were concerned the industry was lapsing next to manufacturing giants in China and India. However, the U.S. plastics industry has only continued to grow over the last 25 years… meaning that more and more positions are opening up.

“We want to make sure [students] have an opportunity and some exposure to something like manufacturing,” said Alice Cable, the executive director of Alliance for Working Together—an organization aimed at promoting careers in manufacturing and production. “We also want it to be something that’s fun for them.”

Several camps that are taking off include the Summer Manufacturing Institute, which helps students discover a passion for making things, Penn College’s summer Engineering Camp, which introduces kids to plastics and polymer engineering and Nuts, Bolts & Thingamajigs, which aims to inspire the next generation of manufacturers.

Certainly, it’s been hard work building excitement for the machining trade, but the results are beginning to show; Anne Cowell, an outreach manufacturing educator, notes that these programs are really hooking kids into how cool plastics manufacturing can be: “The students’ energy is contagious as we work through hands-on investigations and they are so engaged in each experiment.”

We’re excited to see what these camps can do for our industry. An influx of youth with a passion for making things is definitely needed and we hope to see some real engagement in plastics manufacturing once these students graduate from high school and college.

Here at AIP Precision Machining, we’re working hard to attract young students to become interested in plastics. If you’d like to learn more about our presence in the community or our manufacturing capabilities, feel free to contact us.

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