Posted by WS Hampshire, Inc. on | Comments Off on 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.
Posted by WS Hampshire, Inc. on | Comments Off on 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:
Crystalline structure
Material composition
Density
Beneficial material properties
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.
Posted by WS Hampshire, Inc. on | Comments Off on Why Material Selection Can Reduce Downtime
Many types of heavy machinery, equipment, and work vehicles incorporate bearings, bushings, and wear pads in moving parts and assemblies. They keep components aligned and spaced properly, ensure good fit between parts, and reduce wear and tear in spots where parts come together. For example,
Bearings allow for linear and rotational movement
Bushings provide a reliable bearing surface for rotary applications
Wear pads protect surfaces from excessive wear and tear
These components can be made from many different materials with different properties. When choosing the appropriate raw material, it is important to select the one with the best combination of properties that is appropriate for the application at hand.
WS Hampshire brings decades of industry experience and material expertise to develop non-metallic alternatives to traditional bearing, bushing, and wear pad materials used in industrial machinery applications. We have access to both domestic and global sources for raw materials, and full-service CNC machining and fabrication capabilities for nearly unlimited production options.
Read on to learn how bushings, bearings, and wear pads from WS Hampshire can reduce downtime, improve equipment reliability, and extend the lifespan of industrial components.
The Impact of Material Selection on Downtime
Choosing the right material for the job usually means finding the best balance between material strength, hardness, corrosion resistance, and other qualities. This allows for maximum service life of the bearing, bushing, or wear pad, and also keeps equipment and machinery in good repair. And of course, less downtime due to maintenance, repair, or replacement of worn parts.
Engineered composite materials like thermoset plastics, thermoplastics, fiberglass, and laminates have two important jobs. First they must protect equipment and parts, and second, they must be able to withstand the rigors of regular operation, such as:
Chemical Exposure
Load Capacity
Operational Temperature Range
Whether equipment failure is the result of direct damage to parts and mechanisms, or due to a breakdown of protective components like bearings or wear pads, the result is often unplanned downtime, disrupted production, and extra costs.
Extending Part Life Through Material Selection
Selecting an appropriate material for the equipment and application helps to optimize productive time in manufacturing, processing, and other industrial operations. Common non-metal materials for bearings, bushings, and wear pads generally fall into two broad types.
Thermoset plastics
These polymers undergo chemical changes due to heat, UV light, or other catalysts and become “set” in their new shape permanently. They cannot be melted or remolded, and instead will degrade when exposed to high temperatures.
Thermosets tend to be very rigid, hard, temperature-resistant, and structurally stable. They can also be reinforced with fiberglass, carbon fiber, or Kevlar for added strength and durability.
One common example is Ryertex composite materials, which are low friction, high temperature resistant, fiber-reinforced polymers. They can replace metal components in high load, high speed, high temperature applications.
Thermoplastics
In contrast, thermoplastics can be molded, formed, or machined, then can be remelted and formed into a new shape. They are impact, chemical, and corrosion resistant and are good at reducing vibrations in equipment.
Thermoplastics generally have a low coefficient of friction, high mechanical strength, stiffness, and hardness, can be mixed with fillers or rubber to improve flexibility, and take paint or coatings well.
Using the best material for your application helps to extend the service life of machines and equipment by protecting parts that touch or move against each other. Damage and wear from vibration, abrasion, or rust can be greatly reduced with bearings, bushings, and wear pads that are strong, inert barriers between pieces.
As a result, equipment components do not need to be repaired or replaced as frequently, which boosts uptime. Investing in high-quality materials increases initial costs, but there is a return on investment thanks to:
Decreased downtime
Lower labor costs
Reduced maintenance requirements
Less frequent part replacement
Invest in Reliability – Choose WS Hampshire
At WS Hampshire, we specialize in custom fabrication of non-metallic wear pads and other components from materials including Timco Technical Thermoplastics and Ryertex® Composites. With years of experience working closely with a variety of thermoset and thermoplastic materials, we can help you select the best material for your application and develop a custom solution.
Contact us today to learn more about our material selection and capabilities.
Posted by WS Hampshire, Inc. on | Comments Off on Ryertex G10 & G11 for Data Centers, Renewable Energy, and Emerging Technologies
CNC-Machined Ryertex G10 & G11 for Power Systems
In today’s rapidly evolving energy landscape, structural and insulating laminates play a vital role in ensuring efficiency, safety, and durability. Whether in data centers, renewable energy systems, or groundbreaking fusion technology, high-performance materials like Ryertex G10 and G11 are essential for withstanding extreme electrical, thermal, and mechanical stresses. At WS Hampshire, we specialize in CNC machining high-performance composite materials to support your high-demand applications.
Why Ryertex G10 and G11?
Ryertex G10 is a fiberglass-reinforced G10 plastic laminate with epoxy resin, valued for its exceptional electrical insulation, mechanical strength, and heat resistance. G11, a high-temperature variation, offers enhanced thermal stability for challenging environments. These advanced insulating laminates are widely used in data center power systems, solar and wind energy applications, and next-generation technologies like fusion energy.
Key Material Properties:
Ryertex G11 and G10 material properties include:
High Dielectric Strength – Ensures electrical insulation in high-voltage environments.
Superior Mechanical Strength – Provides long-lasting structural integrity.
Heat and Flame Resistance – G11 withstands up to 180°C, making it ideal for demanding thermal applications, while G10 materials perform well up to 130°C.
Chemical and Moisture Resistance – Ensures durability in harsh environments.
Low Thermal Expansion – Maintains dimensional stability under fluctuating temperatures.
CNC-Machined Ryertex G10 & G11 Components for Advanced Power Applications
Our precision CNC machining capabilities allow us to fabricate custom components from G11 and G10 composite materials. We can meet the needs of the following industries:
Data Center Power Infrastructure
Modern data centers require uninterruptible power systems, high-voltage switchgear, and cooling infrastructure to maintain 24/7 reliability.
Battery Energy Storage Insulation – Improves the safety and efficiency of backup power systems.
Cooling System Components – Ensures heat resistance in liquid and air-cooled systems.
Renewable Energy Systems
As solar, wind, and energy storage continue to expand, Ryertex G10 and G11 play a crucial role in ensuring electrical insulation and mechanical durability in these systems.
Wind Turbine Generator Insulation – Supports high-voltage electrical systems in wind power.
Solar Panel Backing & Insulating Sheets – Enhances photovoltaic system efficiency and longevity.
Battery Pack Insulation & Fire Barriers – Provides safety for large-scale energy storage.
Emerging Technologies: Fusion Energy & Advanced Power Systems
With fusion energy and next-generation power systems on the rise, advanced composite materials are needed to withstand extreme conditions.
Plasma Containment Insulation – G11’s high-temperature tolerance makes it ideal for fusion applications.
High-Voltage Insulating Components – Used in superconducting magnets and power transmission.
Cryogenic & Thermal Insulation Structures – Supports emerging energy research projects.
Partner with Us for the Future of Energy
From CNC-machined Ryertex G10 plastic components to custom G11 solutions, WS Hampshire can deliver solutions that meet the toughest electrical and thermal demands. Our expertise in G11 and G10 material machining, combined with our commitment to precision manufacturing, makes us go-to resource for companies seeking cutting-edge solutions in power infrastructure.
Whether you need solutions for data centers, renewable energy, or fusion technology, the experts at WS Hampshire are here to provide high-quality, custom-produced, CNC-machined electrical insulation and composite components.
Contact us today to discuss your project needs and discover how our capabilities can help power the future!
Posted by WS Hampshire, Inc. on | Comments Off on Ryertex FR4 Products
Ryertex is a family of high-performance, fiber-reinforced plastic composites designed for use in demanding industrial applications. These materials are used for electrical insulation or as a metal substitute in high-speed, high-temperature, or high-load applications, or where lubrication loss is a concern. Due to their versatility, Ryertex composites are used extensively across industries like steel and aluminum mills, paper and lumber mills, oil and gas, copper processing, aerospace, mining, and construction equipment.
Among the various grades of Ryertex, Ryertex FR4 stands out for its exceptional combination of mechanical strength and flame-retardant properties. With a reputation for durability and reliability, this grade is a top choice for applications exposed to harsh operating conditions. Below, we’ll discuss the benefits of using Ryertex over other materials as well as the unique properties of Ryertex FR4, in particular.
Why Use Ryertex Over Other Materials
Since its introduction in the 1930s, Ryertex quickly became a valuable metal alternative, especially during World War II when the demand for metal replacements soared. Over time, it has become synonymous with quality, durability, and versatility in industrial components.
Ryertex, specifically the FR4 grade, is one of the most popular grades used in industrial settings due to its high strength and superior thermal properties. Unlike some other materials, Ryertex maintains excellent performance in tough conditions, making it a common choice for wear parts across diverse industries.
While Ryertex is a globally recognized brand, there are numerous other names in the marketplace that are thermoset laminate composites. These include names like Bakelite, Garolite, Lamitex, Micarta, Phenolic, and Resiten. At WS Hampshire, we can cross-reference your application requirements to the corresponding Ryertex solution. With a reputation for producing high-quality, custom-fabricated parts, we can provide Ryertex components such as bearings, bushings, and wear components, all tailored to meet your unique industrial needs.
Ryertex Grade FR4 Properties
Ryertex FR4 is a composite of woven fiber glass and epoxy resin, just as in G10, but with the addition of bromine to give flame-retardant properties. It is the most popular epoxy glass product on the market, with high demand particularly driven by the PCB industry due to its flame retardancy.
Here’s a closer look at the key properties of Ryertex FR4:
Mechanical Strength. Ryertex FR4 is a high-performance, rigid industrial laminate with mechanical properties that exceed most other thermosets.
Temperature Tolerance. It serves as a Class B electrical insulator up to temperatures of 325 °F, ensuring reliable performance in high-temperature environments.
Low Water Absorption. This feature helps Ryertex FR4 maintain its mechanical properties even in high humidity or wet conditions.
Customizability. Ryertex FR4 comes in sheets, tubes, and rods, with custom sizes and fabrication services available from WS Hampshire.
Compliance. Ryertex FR4 adheres to NEMA G10, NEMA FR4, and MIL-I-24768-2 standards.
Because of its beneficial properties, Ryertex FR4 is commonly used for the following applications:
Wear parts such as bushings, bearings, and wear pads
Electrical and mechanical insulation
Power generation and transmission
High-humidity applications
Learn More From WS Hampshire
WS Hampshire is a trusted custom fabricator specializing in thermoset and thermoplastic products. With over 130 years of industry experience, we have earned a reputation for producing high-quality, non-metallic components that can replace metal parts in various industrial settings, helping to reduce weight and operational costs. From custom bearings and bushing to wear pads and sheaves, WS Hampshire provides engineered solutions tailored to your needs.
If you’re looking for reliable Ryertex FR4 products or other advanced thermoset materials, contact us today to learn how we can help with your next project.
Posted by WS Hampshire, Inc. on | Comments Off on Ryertex Composites vs. Timco Thermoplastics: How to Choose
Selecting the Right Material for the Job
Selecting the right material for a project is essential to the durability, performance, and cost-effectiveness of that application. For wear components, composites and thermoplastics offer distinct advantages over metals, including corrosion resistance, weight reduction, and elimination of wear to mating components. When choosing between Ryertex composites and Timco thermoplastics, there are several additional factors to consider based on your specific application.
Let’s look at a direct comparison of the material properties, selection criteria, and applications of each option to decide which material is best suited for your project.
Ryertex Composites: A Closer Look
Ryertex composites are a line of high-performance thermoset laminates that provide exceptional thermal resistance and mechanical strength. These fiber-reinforced plastic composites are created by impregnating layers of glass cloth, canvas, or other fabrics with epoxy, phenolic, or other resins. They are then cured under pressure and heat to create a durable, rigid material suitable for many demanding applications.
Material Properties
Thermal Resistance: Ryertex composites can effectively maintain structural integrity at elevated temperatures, with specific grades capable of performing efficiently at temperatures much higher than their rating.
Mechanical Strength: The material exhibits high impact and compressive strength, making it an ideal solution for load-bearing components.
Low Friction: Certain grades, such as Ryertex® CG, contain graphite to achieve a low coefficient of friction, which enhances the wear life in applications such as bushings and bearings.
Applications
Ryertex composites are often employed in medium to heavy industrial settings for critical applications such as:
Bearings/Bushings
Gears
Wear parts
Thermal/Electrical Insulation
Timco Thermoplastics: Key Features
Timco thermoplastics encompass a broad range of engineering plastics with exceptional machinability, versatility, and recyclability. Unlike thermosets, these thermoplastics can be reformed and melted repeatedly, offering distinct advantages in various applications.
Material Properties
Self-Lubrication: Many thermoplastics are produced with additives that provide self-lubricating properties that enhance the performance of parts, reducing failures and expanding the lifespan of the entire system.
Lightweight: Thermoplastics are typically lighter than thermoset composites, which is beneficial in applications where reducing weight is vital.
Moisture and Chemical Resistance: Thermoplastics have low moisture absorption and are resistant to a broad spectrum of chemicals, ensuring dimensional stability in diverse settings.
Applications
Timco technical thermoplastics are utilized in a broad range of industries and applications, including but not limited to:
Automotive
Consumer products
Electronics
Housings
Gears
Wear-resistant parts
Comparing the Two: A Side-by-Side Analysis
Cost Considerations
Ryertex: Thermoset composites may involve higher processing and material costs but provide superior performance in demanding environments with higher load and temperature demands.
Timco: Thermoplastics typically present a more cost-effective solution for applications requiring complex shapes or large volumes.
Machinability
Ryertex: Thermoset composites such as Ryertex offer enhanced strength and rigidity but are often more challenging to machine.
Timco: Thermoplastics are softer and typically easier to machine, allowing for smooth finishes and complex geometries.
Recyclability
Ryertex: Thermoset materials such as Ryertex cannot be reformed or remelted once cured.
Timco: Timco thermoplastics can be remolded several times and recycled, contributing to enhanced environmental sustainability.
Resistance and Durability
Ryertex: The material offers exceptional mechanical strength and thermal resistance, making it the preferred choice for high-temperature and high-load applications.
Timco: While Timco thermoplastics provide excellent flexibility and chemical resistance, they often have lower thermal resistance than thermosets.
Ryertex Composites and Timco Thermoplastics from WS Hampshire
When comparing Ryertex composites vs. Timco thermoplastics, always consider specific application requirements, such as:
Chemical exposure
Design complexity
Mechanical loads
Thermal conditions
Our industry-recognized brands Timco and Ryertex meet the highest material standards. When combined with our application engineering and technical expertise, these materials can replace traditionally used materials while significantly reducing operating expenses and downtime.
As a leading custom fabricator of non-metallic materials, WS Hampshire offers a comprehensive range of capabilities, including punching, stamping, CNC machining, vacuum forming, and rotary die. We produce innovative OEM-quality fabricated components and small-volume, made-to-order parts, supported by a tailored supply chain program.
Contact us today to learn more about our products and services or for help choosing a material for your project.
Posted by WS Hampshire, Inc. on | Comments Off on Boosting Performance, Extending Lifespan
In industries like construction, forestry, mining, oil and gas, and others that use cranes, bulldozers, excavators, lifts, dump trucks, and other heavy equipment, wear and tear on components is inevitable. Depending on operating conditions and the work being performed, maintenance, repair, and replacement of worn components can cause excessive downtime, labor, and expense.
WS Hampshire specializes in fabricating custom, thermoplastic and composite parts and components that are durable and tailored to the needs of each application. We work with a range of high-performance materials that outperform traditional materials in heavy equipment, even in harsh conditions.
Learn more about the benefits of developing custom components for heavy equipment and read how our team engineered a solution for a customer that dramatically reduced maintenance work and expenses.
The Power of Customization
Heavy equipment is complex and must withstand hundreds or thousands of hours of repetitive motion at a job site or facility. Moving heavy loads, hoisting equipment or material, operating in excessive hot, cold, or wet conditions, with little down time take a toll on external and internal components.
Time and money spent replacing components means downtime that impacts other departments or customers and eats into profitability. Fortunately it is often possible to engineer replacement components from composite materials that are more durable, easier to maintain, and more convenient to use such as:
Nose Cone Bearing
Body Pivot Bushings
Wire rope Sheaves and Pulleys
Wear Plates and Slide Pads
Guide Pads for Extension Cylinders
Rollers and Wheels
Hose Clamps and Guides
Dust Seals
Scraper Blades
Outrigger Float Pads
Key Benefits of Custom Components
Custom components are designed specifically for the machine and application in question. Material properties, dimensions, and any special features like colors or finishes, can be included to optimize performance and wear over time. There are several benefits to this custom approach:
1. A Solution Tailored to the Application
Custom parts and equipment are developed to be fully functional for a specific application, so there is no trade off between performance and one-size-fits-all design. Parameters that can be customized include:
Material composition
Performance and durability
Shape
Dimensions
Tolerances
2. Competitive Advantage
By upgrading heavy equipment with custom components that enhance efficiency and performance, less production time is lost to maintenance, repair, or developing workarounds for an application. More time on-task is a competitive advantage and boosts profitability.
3. Enhanced Performance
Custom components can be designed to achieve specific goals such as:
Enhanced performance
More time between repairs
Longer useful life
Process efficiency
Improved finished product quality or higher yields
4. Cost Efficiency
While custom engineering and manufacturing may be more costly than standardized, ‘off the shelf’ parts, there are often long-term savings to be gained. These include:
Less frequent replacement of durable composite materials
Decrease downtime and boost productivity
Minimize maintenance costs
Reduce the need for modifications to other components
5. Integration and Compatibility
Custom-engineered components are made to fit equipment precisely and seamlessly integrate with other parts of a system. This reduces the risk of damage or downtime from ill-fitting or incompatible standard parts.
6. Flexibility and Innovation
Custom engineering fosters innovative state-of-the-art components that set new standards for the equipment, application, and industry. Each component is an opportunity to refine operations and benefit from new ideas.
Real-World Success
This real-world example highlights how changing material used for a critical component in a steel mill saved both time and money.
Replacing Metal with Nylon Makes Major Impact
A specialty steel mill sought ways to reduce downtime and expenses due to a slipper pad on their rolling mill. The aluminum bronze pad was heavy and cumbersome, and required the use of a crane each time it was replaced. With pads wearing out frequently, the mill determined a new solution was needed.
Our team evaluated the requirements for cost and performance as well as factors like weight, operating conditions, and expected lifespan of the pad. A self-lubricating, impact-modified cast nylon material that matched the property profile for the pad was selected. Once fabricated, the new pad was 80% lighter than the original and could be replaced safely without the need for a crane.
We monitored the new pad for signs of wear for over a year to validate the solution. Not only did this nylon component meet the basic performance goals for the project, the new pad lasted longer and even eliminated wear on the mating spindle – an unexpected additional benefit. Pleased with the outcome, the mill chose to standardize all of their parts with WS Hampshire.
Invest in Your Equipment with WS Hampshire
WS Hampshire brings decades of experience with non-metallic and composite materials to custom manufacturing. Our capabilities include CNC machining, punching, stamping, rotary die, vacuum forming, and assembly. We are dedicated to meeting or exceeding our customers’ expectations and requirements for each project.
Contact us to learn more about getting the most from your heavy equipment with custom components from WS Hampshire.
Posted by WS Hampshire, Inc. on | Comments Off on Nylon vs. Delrin®
Two Strong Contenders in the World of Plastics
When selecting materials for industrial or consumer applications, nylon and Delrin® often top the list of options. These engineering-grade plastics are both known for their durability, versatility, and impressive mechanical properties. However, they have distinct qualities that make them each better choices for different applications. While nylon is celebrated for its toughness and flexibility, Delrin® excels in precision and chemical resistance.
Understanding the unique strengths and limitations of materials is key to choosing the right one. This guide will explore the mechanical properties, chemical resistance, and common applications of these two popular materials so you can make an informed decision.
Nylon: A Versatile Engineering Plastic
Nylon is best known for its exceptional tensile strength and flexibility. These qualities make it ideal for components like sheaves, gears, and bushings that must endure heavy, repetitive loads. In addition, nylon effectively absorbs shocks and vibrations, making it a preferred choice in high-stress environments like hoisting and pulley systems.
Certain environmental factors, particularly moisture absorption, can influence nylon’s performance. In humid conditions, nylon can swell, which may affect its dimensional stability. Despite this drawback, it remains a top choice for applications that require wear resistance and durability.
Chemical Resistance
Nylon is resistant to many hydrocarbons, oils, and lubricants, performing well in applications with mild chemical exposure. However, it is less effective against strong acids or bases and may require additional treatments to withstand harsher environments.
Top Applications
Nylon’s strength and flexibility make it suitable for a wide range of uses, including:
Automotive components
Industrial fasteners
Consumer products
Machine parts
While the material’s effectiveness may vary based on the given environmental conditions, its versatility ensures it can meet the demands of many industries.
Delrin®: High-Performance Acetal Resin
Delrin® is a type of polyoxymethylene (POM). This material is widely valued for its stiffness and high dimensional stability. Unlike nylon, Delrin® resists moisture absorption, allowing it to maintain its shape and mechanical properties over time. This makes it an excellent choice for precision parts that require steady performance.
Delrin® also features a low-friction surface, which allows it to operate smoothly in sliding or rotational mechanisms. This property expands its potential uses to industries where precision and reliability are paramount.
Chemical Resistance
Delrin® resists most solvents, oils, fuels, and weak acids. However, it may be affected by exposure to strong acids. This chemical resistance makes it a preferred material for environments where contact with corrosive substances is common.
Best Applications
Delrin® is an ideal material for the following applications:
Bearings
Pulleys
Conveyor belts
Fuel system components
Medical devices
Electrical insulation
Its ability to withstand chemical exposure and maintain dimensional stability under consistent loads makes it a standout choice for demanding environments.
Comparing the Two: Nylon vs. Delrin®
When comparing nylon and Delrin®, both materials bring distinct advantages. On the one hand, nylon’s flexibility and impact resistance make it ideal for load-bearing components like sheaves, gears, and bushings. However, its susceptibility to moisture absorption can compromise its performance in humid conditions.
Conversely, Delrin® offers superior rigidity, dimensional stability, and low friction, which is essential for precision parts like bearings and pulleys. Additionally, its higher chemical resistance allows it to perform reliably in chemically intensive environments.
Mechanical Properties Overview
Property
Nylon
Delrin (POM)
Tensile Strength
12,000 psi
10,000 psi
Elongation at Break
300%
150%
Flexural Modulus
2.6 - 3.0 GPa
2.4 GPa
Hardness (Rockwell M)
82
90
Friction Coefficient
0.2 - 0.3
0.2 - 0.3
Wear Resistance
High
Very High
Machinability
Good
Excellent
Thermal Stability
Up to 223 °C (Nylon 6)
Up to 180 °C
Choose the Right Material for Your Needs at W.S. Hampshire
Choosing whether you need nylon or Delrin® ultimately depends on your specific application’s needs. For components requiring flexibility, shock absorption, and wear resistance, nylon is an excellent choice. If your application demands dimensional stability, low friction, and chemical resistance, Delrin® is likely a better option.
W.S. Hampshire, Inc. provides high-quality materials tailored to your project’s needs. Our team of experts can guide you in selecting the best plastic for your application, whether that’s nylon, Delrin®, or another advanced material. You can trust us to deliver durable and reliable solutions that meet the demands of your industry.
Contact us today to find the perfect material for your next project.
Posted by KevinP on | Comments Off on Understanding CNC Machining Tolerances to Maximize quality, reduce cost, and navigate design challenges
Eli Whitney, the inventor of the cotton gin, is credited with the concept of interchangeable parts. During a presentation to the United States Congress in 1801, he illustrated how all of the components needed for an assembly should be produced according to a set of exacting standards— in other words, to specific dimensions and tolerances—thus ensuring that the firing pin or gun barrel from one musket will fit into any other musket. His idea helped pave the way for the Second Industrial Revolution and what became known as the American System of Manufacturing, which has the standard method of part design and print for almost two centuries.
Although the concepts of component interchangeability and dimensional tolerancing have since become an accepted part of manufacturing, unfortunately, the lack of understanding and proper use of dimensional tolerancing can cause many problems. For instance, an overly stringent tolerance might require that parts go to a secondary operation and/or extra “finishing” passes, unnecessarily increasing costs and lead-time. Tolerances that are “too loose” or that aren’t in line with those of mating parts can make assembly difficult if not impossible, leading to required rework, or in the worst case, making the finished product unusable.
To help avoid these unpleasant situations, this design tip includes some guidelines on how to properly apply part tolerances, along with a few definitions of the more commonly used callouts.
The World of Engineering Thermoplastic and Thermoset Materials – How They Differ From Metals
First, it is important to understand that, unlike metals and ceramics, with engineering thermoplastics the property-determining particles are not atoms, atomic cores and ions, but organic macromolecules, and this differs greatly as compared to the lattice structure of metals.
These macromolecules can also differ within a plastic in terms of their size and chemical structure, meaning that these factors exert a far wider influence on the properties of the material as compared to metals. Most plastics are termed “semi-crystalline”, meaning they have both crystalline and amorphous structures within the material. Such a complex structure enhances some properties (such as impact resistance), but always results in compromises in material stability as compared to metals.
As a result of these differences, plastics offer lower dimensional stability in comparison to more historically specified
Non-metallics have higher coefficient of thermal expansion, lower rigidity and greater elasticity
The moisture absorbing properties of plastics, which can result in phenomena such as swelling of the material and the respective dimensions, also have a determining role to play (particularly in the case of polyamides [nylons]).
Combined, these attributes add to the difficulty of adhering to very tightly specified tolerances during machining, in shipment and in storage. Therefore, proper storage of engineering thermoplastic components over a long period of time (especially in summer months) is required to maintain the dimensions achieved during machining. High heat (over 80F), especially combined with high humidity, is to be avoided.
To a lesser extent, this is also true of thermoset materials – the various “phenolic” formulations. The fabric or fiberglass matrix makes these more stable than thermoplastics, but still less than metals.
The recommended guideline to use when determining machining tolerances is a minimum of 0.2% of the nominal value (Tighter tolerances are achievable when using very stable and fiber-reinforced composite materials).
Standardized Tolerances for CNC Machining
At WS HAMPSHIRE, our standard machining tolerance is +/- 0.005 in. (0.13mm) on standard L/W/T dimensions. Hole locations and other critical dimensions can be held more closely. This means any part feature’s location, width, length, thickness, or diameter will not deviate by more than this amount from nominal. For example, the 1 in. (25.4mm)-wide bracket you’re planning to order will measure between 0.995 and 1.005 in. (25.273 and 25.527mm) across, while the 0.25 in. (6.35mm) hole on one leg of that bracket will come in at 0.245 to 0.255 in. (6.223 to 6.477mm) diameter.
When specifying feature locations, be sure to reference the datums, or “start measuring from here”, points. This is usually from one or more edges, making clear where the centering point of a given feature needs to be located.
Something that usually helps in those discussions is sending us an assembly drawing, and/or drawing of mating parts. This allows cross-reference and can prevent “tolerance creep”, which is where individual tolerances all tend to one side which can hinder part alignment, especially at attachment points.
Tolerancing Guidelines for CNC Machining
Also, be aware that these are bilateral tolerances. If expressed in unilateral terms, the standard tolerance would read +0.000/- 0.010 in. (or +0.010/- 0.000 in.) while a limit-based tolerance in our bracket example would be 1.005 / 0.995 in.
All are acceptable, as are metric values, provided that you spell them out on the design. And to avoid confusion, please stick with one system and use “three place” dimensions and tolerances, avoiding the extra zero in 1.0000 or 0.2500 in. unless there’s an overriding reason to do so, which may require further discussion.
Surface Roughness Considerations for Machining Tolerances
There’s more to part tolerancing than length, width, hole size, etc. There’s also surface roughness, which in the standard offering is equal to 63 µ in. for flat and perpendicular surfaces, and for curved surfaces, 125 µ in. or better.
This is an adequate finish for most uses, but for cosmetic surfaces on certain parts, we’re generally able to improve appearance through adjusting the feeds and speeds of the equipment. For wear surfaces, the material will smooth out during operation. If aesthetics are important, that needs to be specified on the print and understood (samples always help!)
Geometric Dimensioning and Tolerancing
Here’s another consideration. As mentioned earlier, we can accept GD&T tolerancing. This provides a deeper level of quality control that includes relationships between various part features as well as form and fit qualifiers. Below are a few of the more common ones:
True position: In the bracket example cited earlier, we called out the hole location by specifying X and Y distances and their allowable deviation from a pair of perpendicular part edges.
Flatness: Milled surfaces are generally quite flat, but due to internal material stress or clamping forces during the machining process, some warpage can occur once the part has been removed from the machine, especially on thin-walled plastic parts. A reasonable GD&T flatness tolerance controls this by defining two parallel planes within which a milled surface must lie.
Cylindricity: For the same reasons that most milled surfaces are quite flat, most holes are quite round, as are turned surfaces. However, using a +/- 0.005 in. (0.127mm) tolerance, the 0.25 in. (6.35mm) hole in the bracket example could potentially be oblong, measuring 0.245 in. (6.223mm) one way and 0.255 in. (6.477mm) the other. Using cylindricity—defined as two concentric cylinders inside of which the machined hole must lie—manufacturers eliminate this unlikely situation.
(NOTE – due to composites higher coefficient of linear thermal expansion, sometimes a slight “slot” is preferred as it allows part movement without buckling)
Concentricity: The rings on a bullseye are concentric, just as the wheels on your car are concentric to the axle. If a drilled or reamed hole must run perfectly true to a coaxial counterbore or circular boss, a concentricity callout is the best way to assure this.
Perpendicularity: As its name implies, perpendicularity determines the maximum deviation of a horizontal machined surface to a nearby vertical surface.
There are additional considerations to GD&T, including parallelism, straightness, profile, and angularity, all of which should be indicated on the print. Again – composites are less rigid than metals, and slight irregularities will conform to the mating surfaces, so avoid using “metal-think” when specifying these additional features.
Summary
Remember that composites are less structurally stable than metals, which requires composite-specific tolerancing but also allows for greater conformability with mating parts
Don’t over-specify tolerances that aren’t actually required, it adds cost rather than functionality
Fine-tuning tolerance dimensions in your designs for CNC machined parts can help maximize those parts’ quality and reduce cost
We at WS HAMPSHIRE are happy to discuss appropriate part dimensioning, as well as material alternatives and other design considerations with your design team – with over 125 years of non-metallic manufacturing experience, we can help! Give us a call!
Posted by WS Hampshire, Inc. on | Comments Off on What Is FRP Material?
Fiber-reinforced plastic (FRP) is a composite material characterized by its robustness and versatility. It is an important material in numerous construction and civil engineering applications, including electrical insulation, structural components, bearing and wear applications, and metal substitutes. To see if it’s the right material for your project, learn more about the characteristics of FRP material and how it is made.
FRP Material Characteristics
FRP is a composite material that consists of a polymer matrix and reinforcing fibers, typically glass or carbon. This unique blend offers an effective alternative to traditional materials like wood, steel, or aluminum, which can degrade over time. FRP is renowned for its strength, lightweight nature, and corrosion resistance, making it a prime choice for many applications.
FRP material offers an impressive array of features that cater to a wide range of industrial needs:
Corrosion resistance: This makes FRP perfect for harsh environmental conditions.
High strength-to-weight ratio: FRP is ideal for applications requiring durability without the added weight.
Parts consolidation and design flexibility: Because of its strength, lightness, low thermal conductivity, and other properties, FRP can replace multiple materials and fasteners in an assembly, improving design flexibility.
Radar transparency: Glass-fiber-reinforced plastics are transparent to radar equipment, so they are often used in enclosures or canopies to hide communications devices in buildings.
Fire characteristics: FRP can be engineered to meet various fire codes in building construction.
Non-conductivity: FRP made with glass fibers are non-conductive and often used as electrical insulation.
Dimensional stability: Many FRP materials can be engineered to have a zero coefficient of thermal expansion, meaning they will not expand or contract as the temperature changes.
Production repeatability: FRP products have good consistency across high-volume production runs.
Customizable appearance: The composite material can be designed to meet any aesthetic requirement.
How Is FRP Material Made?
FRP is made through pultrusion, which melds raw fibers and resin to forge a composite with the strength of steel but without the high weight. The pultrusion process is as follows:
Material selection: First, the appropriate fibers and resin are selected. The choice depends on the application’s requirements, like strength, flexibility, corrosion resistance, and thermal insulation. Fibers could be glass, carbon, or aramid, each offering distinct properties to the composite. The resin, acting as the matrix, could be polyester, vinyl ester, or epoxy, based on the environmental resistance required and the mechanical properties desired.
Mold or tool preparation: A mold or tool must be prepared. This step is crucial as it defines the FRP’s dimensions, shape, and surface finish. Molds can be made from metal, composite, or plastic, and they must be cleaned and coated to prepare for resin infusion.
Layup or preform process: During this stage, the fibers are laid out or pre-formed according to the direction and orientation needed for optimal strength and performance in the final product.
Infusion: The laid-out fibers are infused with resin, ensuring every fiber is thoroughly saturated. This process is critical for creating a cohesive and uniform material where the resin matrix supports the fibers, providing strength and durability.
Curing: After the fibers are infused with resin, the composite needs to be cured—a process that solidifies the resin, binding the fibers into a solid mass. This step can occur at room temperature or be accelerated using heat. The curing process transforms the soft and malleable resin-fiber mixture into a rigid and sturdy material that retains its shape under physical stress.
Finishing: The final stage involves applying the necessary finishes to the FRP, like trimming, drilling, painting, or coating for aesthetic purposes or additional protection. This process guarantees the FRP meets the specific requirements for its use.
FRP From WS Hampshire
FRP offers a unique blend of strength, versatility, and durability. Its unique characteristics make it an ideal choice for many applications, from infrastructure projects to innovative designs in the automotive industry. With over 100 years in the nonmetallic materials fabrication industry, WS Hampshire is a leading provider of FRP materials, Ryertex® and EXTREN® product lines.
