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Ten Industries That Rely on Custom Plastic Machining

The plastic fabrication industry serves a diverse cross-section of commercial and industrial interests. Innumerable products require custom plastic components to optimally suit their applications, driving constant market demand for experienced plastic parts fabricators dedicated to quality and service. Read on to learn more about the advantages of custom plastic machining and the industries that most commonly benefit from these services.

Benefits of Custom Plastic Machining

Choosing to incorporate custom-machined parts of durable plastic can be highly advantageous for your end products. The primary benefits of this process include:

Top 10 Industries That Rely on Custom Plastic Machining

Its high versatility lends custom plastic machining to many different markets.

Military

The military is one of the top markets for plastic fabrication services. Military organizations capitalize on the benefits of machining to generate high volumes of strong yet affordable components ranging from personal protective equipment (PPE) and gear to parts for mechanical and electrical systems.

Aviation/Aerospace

Since 1970, these industries’ use of plastic components has quadrupled. Companies are swapping metal for plastics to create FAA-compliant parts that have comparable strength at a fraction of the weight. Maximizing strength-to-weight ratios in this way helps dramatically cut down on fuel costs (approximately $1,000 saved for every pound taken off a plane’s weight over the craft’s lifespan).

Telecommunications

Telecom companies depend on custom plastic machining services to rapidly manufacture long-lasting parts that improve network performance and reduce downtime. With the potential to dissipate static, plastics can also provide high corrosion and thermal resistance, all properties that help telecom components protect sensitive electrical devices against damage.

Consumer Electronics

Plastic parts manufacturers also assist the modern consumer electronics industry. Lightweight, durable machined components of hard plastic provide an affordable means of protecting cellular phones, computers, and other sensitive or portable electronic devices.

Medical

The healthcare sector depends on highly specialized, precision plastic components that are long-lasting, simple to clean, and meet strict regulatory standards. Alternatively, the industry also utilizes disposable plastic products that must be produced economically. Custom plastic machining can achieve these goals affordably and efficiently.

Construction

While plastics aren’t typically the ideal material for structural applications, the construction industry still relies on many custom-machined plastic components. Common examples include tools and hardware that are economical and lightweight yet durable.

Oil and Gas

The oil and gas sector requires highly specialized plastic parts capable of withstanding extremely high temperatures, pressures, and loads. Plastic also resists many types of chemicals and oil while supporting operational safety, allowing companies to machine components that are fully compliant with all necessary industry standards, including ISO, ASME, API, NACE, and Norsok.

Agriculture

From irrigation systems and spray tanks to augers and greenhouse components, plastic machined parts are indispensable to modern agriculture. In fact, the U.S. agricultural sector utilizes an estimated 1 billion pounds of plastic per year. Custom components of plastic construction help agricultural operations protect the land and crops from weeds, insects, and even excessive sunlight and moisture loss in dry locations.

Food

Products machined from food-safe plastics help food and beverage companies meet FDA regulations. From safe food storage to utensils, the food and beverage market reaps the benefits of custom plastic goods.

Waste Treatment

Plastic machined products are ideal for wastewater treatment applications, due to their material’s high chemical resistance and low porosity. Custom plastic valves, pipes, rollers, and screens don’t absorb moisture or contaminants, helping improve sanitation at waste treatment facilities.

Custom Plastic Machining at WS Hampshire, Inc.

Custom plastic machining provides several key benefits, facilitating rapid prototyping and scalable production. Advancements in the plastic machining industry make increasingly complex parts possible while reducing costs and products’ time to market. At WS Hampshire, we pride ourselves on being at the forefront of plastic machining, creating high-quality components tailored to your specific applications. To learn more about our capabilities for custom production and how we can support projects in your industry, contact us today.

Quality Cast Nylon Sheaves From WS Hampshire

Nylon is a durable thermoplastic that offers exceptional strength and versatility. This material is an excellent alternative to metal for custom nylon sheaves and heavy equipment sheaves. Not only are they strong and resist wear and tear, nylon sheaves reduce wear on ropes and wires in a pulley system, for less maintenance and a longer useful life. Here we’ll look at how nylon and metal compare for sheave applications and some of the advantages cast nylon offers.

Cast Nylon vs. Metal Sheaves

Traditional sheaves are often made from steel or aluminum alloys; however, in many applications, cast nylon non-metallic sheaves are just as functional, with these additional benefits:

• Corrosion Resistance. Nylon has excellent saltwater and rust corrosion resistance, making it a durable choice for many outdoor and marine applications.
• Durability. Nylon’s modulus of elasticity results in minimal deflection under load, which reduces the stress on wire ropes and extends their lifespan.
• Lightweight. Cast nylon pulley sheaves weigh a fraction of steel ones and nearly half the weight of aluminum, which means they make industrial and heavy pulley systems lighter and easier to handle and maintain.

Key Applications in Heavy Equipment

With high tensile and compressive strength, cast nylon sheaves can be used for many heavy equipment applications including:

• Forklifts and Telehandlers. Reduces wear and improves maneuverability on mechanical systems.
• Hoists and Cranes. The lightweight nature of these components reduces the overall load on structural elements of lifts and increases the lifting capacity.
• Marine Equipment. High resistance to saltwater corrosion helps extend the service life.

Benefits of Cast Nylon Sheaves

Cast nylon material has a number of benefits for reducing overall weight of components and pulley systems, especially where frequent manual operation is involved. Nylon sheaves are durable in exposed conditions, and can help prolong the useful life of wire rope and cable.

Lighter Weight for Easier Handling

• Enhanced Safety. Lighter components allow for easier maintenance and installation.
• Increased Load Capacity. Lower sheave weight affords a higher payload, particularly in boom point applications.

Weather Resistance and Corrosion

• Increased Longevity. Compared to metal sheaves, the non-corrosive properties of cast nylon sheaves offer lasting longevity.
• Reduced Maintenance. Eliminates the need for frequent rust inspections or application of protective coatings.

Extended Wire Rope and Sheave Life

• Lower Operational Costs. Requires fewer maintenance interventions and less frequent replacements.
• Prolonged Wire Rope Lifespan. High compressive strength results in a reduced cushioning effect and less contact pressure, which decreases wear on the internal rope.

Why WS Hampshire Leads in Nylon Sheave Fabrication

Custom Fabrication Capabilities

WS Hampshire specializes in manufacturing custom nylon sheaves that meet the specific requirements of an application. In addition to custom castings, our services include:

• Assembly. We can incorporate sleeves, snap rings, bearings, and other components in sheave assemblies to meet customer requirements.
• Precision Machining. Precision CNC machining is efficient and virtually eliminates variation from part to part.

Proven Performance Across Industries

With over a century of proven industry experience, WS Hampshire has served a range of industries from construction to oil and gas to mining and beyond. We offer custom fabricated non-metallic parts and components from a wide range of the highest quality polymers, thermoplastics, and other composite materials. Our team is committed to providing each customer with innovative materials and products of OEM quality for large-scale production as well as low-volume components.

Choosing the Right Material and Design

Originally developed by DuPont in 1935, nylon, or polyamide, has come a long way since its initial use in parachutes and stockings. Common types of nylon include type 6/6 for extrusion and type 6, which can be extruded or cast. Nylon materials have a combination of favorable qualities that make it a good choice for applications in challenging environments, including a high strength-to-weight ratio, corrosion resistance, and general toughness.

Material Grades for Load and Speed

Unmodified cast nylon, is also a durable and strong material, suitable for general applications, offering exceptional hardness and high strength.

Because nylon components are cast by mixing two separate streams of liquid that react, it is possible to incorporate additives that enhance its performance. One common option is molybdenum disulfide-filled nylon, sometimes called “moly.” The addition of molybdenum disulfide enhances nylon’s load-bearing strength and wear resistance.

Design Support for OEM Needs

WS Hampshire provides design, engineering, and material selection support to ensure manufacturability and performance according to design intent. Our knowledgeable team can provide engineering assistance for optimal sheave design, along with help in selection the best type and grade of nylon for the application.

Nylon Sheaves Built to Last by WS Hampshire

Nylon is an affordable and durable material that typically outperforms traditional metal sheaves in heavy equipment applications. At WS Hampshire we manufacture high-quality, custom cast nylon pulley sheaves that withstand even the most harsh operating conditions and heavy loads.

Contact us today to learn more about our selection of nylon and other non-metallic materials, and our custom manufacturing capabilities.

Acetal Copolymer vs. Delrin: Why Two Types?

Acetal polymers are used in a variety of applications from bushings and gears to rollers and gaskets. They are valued for their exceptional mechanical properties, dimensional stability, and low coefficient of friction, which is why they are used for a wide range of applications. Two primary variants are acetal copolymer and acetal homopolymer, also known as Delrin. While they are often used interchangeably with success, there are some important differences between these two thermoplastics. Here, we’ll look at the characteristics of both, and how they differ.

Acetal Copolymer: A Versatile Choice

Acetal copolymer, or polyacetal and polyoxymethylene (POM), is a semi-crystalline thermoplastic produced by copolymerizing formaldehyde with other monomers.

Key Properties of Acetal Copolymer

• Chemical Resistance. Superior resistance to hydrolysis, strong alkalis, and thermal oxidative degradation, making it suitable for applications involving exposure to harsh chemicals and high temperatures.
• Reduced Porosity. Minimal centerline porosity and higher density, which ensures consistent mechanical properties and low risk of voids.
• Dimensional Stability. Excellent dimensional stability, which is critical for precision components requiring tight tolerances.​
• Glass Reinforcement. Can be chemically bonded to glass fibers for added strength.
• Durability. Low coefficient of friction for high wear and abrasion resistance.

Common Applications

Acetal copolymer is often used for applications where strength, stiffness, and low surface friction are essential, as well as in environments with temperature or humidity fluctuations.

• Medical Devices. Acetal copolymer is the ideal plastic in components requiring high chemical resistance and dimensional stability.
• Food Processing Equipment. With acetal copolymer’s resistance to hydrolysis and chemicals, it is ideal for parts exposed to cleaning agents and varying temperatures.
• Automotive Fuel Systems. Acetal copolymer’s robust chemical resistance is why it is used for fuel system components.

Delrin: Superior Strength and Rigidity

Delrin is the widely-used brand name for acetal homopolymer. This material is synthesized through the polymerization of formaldehyde, resulting in a uniform molecular structure. Because it is similar to acetal copolymer, Delrin material properties are similar; however, a major difference is that Delrin’s uniform crystalline structure improves its ability to bear cyclic loads without deforming.

Key Properties of Delrin

• High Mechanical Strength. Approximately 10% to 15% higher mechanical strength than acetal copolymers, making it suitable for load-bearing applications.
• Stiffness and Creep Resistance. Enhanced stiffness and creep resistance to ensure components maintain their shape under prolonged stresses, including high temperatures and humidity.
• Flex Fatigue Resistance. Superior resistance to repetitive stress and flexing, extending the lifespan of parts subjected to cyclic loading.

It is important to note that Delrin has lower chemical resistance than acetal copolymer. It is also prone to a phenomenon called centerline porosity, in which the middle of a piece may become more porous after cooling, making it more susceptible to bacterial or mold growth in some applications.

Common Applications

• Gears and Bearings. Delrin’s strength and wear resistance is ideal for high-precision gears and bearings.
• Fasteners and Snap-Fit Components. Applications requiring high stiffness and the ability to withstand repeated assembly and disassembly use Delrin.
• Automotive Safety Systems. Critical safety components in vehicles that require mechanical reliability use Derlin.

Comparing Acetal Copolymer and Delrin: Key Differences

When evaluating acetal copolymer and Delrin for an application, several critical differences emerge:

• Mechanical Properties. Delrin offers higher tensile strength, stiffness, and impact resistance compared to acetal copolymers, making it ideal for structural applications requiring robust mechanical performance.
• Chemical Resistance. Acetal copolymers exhibit better resistance to hydrolysis and strong alkaline environments, making them better for applications with water and chemical exposure.
• Centerline Porosity. Delrin is more prone to centerline porosity, where voids form during cooling, potentially compromising mechanical integrity. Acetal copolymers offer more uniform material consistency and higher density.
• Thermal Stability. Delrin maintains its mechanical properties over a broader temperature range, providing better performance in extreme temperatures than acetal copolymers.

Make an Informed Decision With W.S. Hampshire

The choice of acetal copolymer vs. Delrin is a common one for many applications. While the two thermoplastics share many properties and characteristics, they have some differences that make them more or less suitable for certain applications. It’s important to be aware of how both materials and components made from them behave in the real world.

At WS Hampshire, our experts can help you assess the requirements of an application to determine the best material options. We are a full-service, custom, non-metallic materials fabricator, and we produce high-quality OEM components and parts for various industries. Contact us to learn more about our capabilities and range of materials.

Advantages of Using Engineering Thermoplastics in Industrial Applications

When it comes to demanding industrial applications, material performance is key. Parts need to endure punishing environments, like exposure to extreme temperatures and harsh chemicals, while maintaining their integrity. That’s why many manufacturers turn to engineering thermoplastics to ensure product longevity or reliable equipment functionality. These versatile materials can outperform metals and traditional plastics in durability and efficiency.

What Is Thermoplastic Material?

Thermoplastic materials are polymer resins that become soft and moldable when heated and then harden as they cool. This process is reversible and repeatable, however, which means that manufacturers can reshape and remold thermoplastic materials several times without altering their chemical structure.

Unlike thermoset plastics, which undergo a chemical change and harden permanently after curing, thermoplastics become homogenized liquids that retain their ability to be reprocessed. This physical rather than chemical change makes them ideal for both custom fabrication and sustainable reuse. Numerous types of thermoplastics are available to manufacturers, each with its own:

Benefits of Using Engineering Thermoplastics in Industrial Applications

Engineering thermoplastics offer the industrial sector myriad benefits for manufacturing products.

Longevity and Sustainability

Unlike single-use consumer plastics, engineering thermoplastics are designed for durability. These materials are energy efficient to manufacture and lend your products extended lifespans, even in high-friction or chemically harsh environments. Many thermoplastics can also be recycled, lessening the burden on important resources and making them a more sustainable alternative to some metals or thermosets.

Electrical/Thermal Insulation and Flame Ratings

For electrical applications or those that expose parts to extreme temperatures, thermoplastics excel as fire-resistant electrical and thermal insulators. They offer high dielectric strength and can be manufactured to meet UL 94 V-0 flame ratings. Their ability to manage heat and prevent electrical conductivity makes them ideal for switchgear, enclosures, and other electronic housings.

Temperature Resistance

That said, manufacturers can formulate thermoplastic materials to either insulate against or conduct heat, depending on your application and heat transfer needs. Thermoplastics are known for their excellent thermal resistance. High-performance materials like PEEK and PTFE can withstand both cryogenic and high-heat conditions without deforming.

Chemical Resistance

Advanced thermoplastics offer excellent resistance to acids, alkalis, and solvents, making them ideal for industries like food processing, medical manufacturing, and chemical handling. This chemical stability helps maintain products’ structural integrity in environments where metals might corrode or degrade.

UV Resistance for Outdoor Use

Outdoor applications present a unique challenge, with materials exposed to prolonged sunlight. To address this, you can select thermoplastics enhanced with UV-resistant additives to protect against degradation. Materials such as HDPE, PTFE, and PEEK are excellent choices for components that must withstand UV radiation and external use.

Reduced Wear on Mating Parts

Thermoplastics help minimize wear on critical components that come into direct contact. Their low coefficient of friction helps protect mated parts made of aluminum and other soft metals. In many designs, thermoplastics serve as a sacrificial layer, preserving the life of more labor-intensive or costly components.

Self-Lubricating Properties

Certain thermoplastics can be engineered with self-lubricating additives that lower the need for ongoing maintenance. These materials minimize downtime by reducing the risk of mechanical failure due to friction or improper lubrication. Self-lubricating thermoplastics are advantageous for operations focused on reliability and total cost of ownership.

Weight Reduction and Enhanced Affordability

Typically, thermoplastics weigh roughly one-seventh the weight of steel. This reduction directly impacts product weight and the ease of installation and handling. Lighter components reduce the strain on lifting equipment, if any is needed at all. They also cut material and shipping costs and minimize vibrations and noise in dynamic systems. These advantages contribute to workplace safety and operational efficiency, as well.

Cost Savings Over Time

If you want long-term cost savings, thermoplastics are a good option. They’re easier to process, require less maintenance, and offer a longer lifespan than alternative materials. They also support lean manufacturing strategies by streamlining production and reducing system downtime and material waste, leading to measurable cost savings for manufacturers.

Partner With WS Hampshire

At WS Hampshire, we go beyond standard materials — we deliver engineered thermoplastic solutions. With deep technical knowledge, an expansive global sourcing network, and in-house manufacturing capabilities, we can help you find the right thermoplastic material to meet your needs.

Our team specializes in matching thermoplastic properties to performance requirements, with a focus on reducing downtime and cutting costs in our clients’ operations. To optimize your components with durable, high-performance thermoplastics, contact WS Hampshire today. You can also gain a better understanding of the benefits of thermoplastics by downloading our eBook, Advantages of Using Engineering Thermoplastics.