Plastic machining looks easy until you melt the part. Heat builds up fast in low-conductivity polymers.
Plastic Categories
- Soft thermoplastics (PE, PP, ABS) — Easy but burr-prone
- Engineering plastics (Delrin/POM, Nylon) — Best plastics to machine
- High-performance (PEEK, PEI, PSU) — Stable but melt at edge
- Filled plastics (glass, carbon) — Abrasive, eat carbide fast
Tool Material
- Unfilled plastics: HSS or polished carbide. Sharp edge = clean cut.
- Glass-filled: Solid carbide with TiAlN coating
- Carbon-filled: PCD or diamond-coated for production
Geometry Rules
HIGH POSITIVE rake (15-25°) and sharp edges. For end mills:
- 2-flute for soft plastics (chip evacuation)
- 3-flute for engineering plastics
- Single-flute for very soft plastics like PE/PP
Cutting Parameters
| Plastic | Vc (m/min) | Feed (mm/tooth) |
|---|---|---|
| ABS | 200-400 | 0.10-0.20 |
| Delrin/POM | 300-600 | 0.15-0.30 |
| PEEK | 200-400 | 0.10-0.20 |
| Polycarbonate | 150-300 | 0.05-0.15 |
Coolant
Air blast or mist for chip clearing. Some plastics absorb water — never flood. Polycarbonate stress-cracks with some coolants.
Browse end mill catalog for plastic machining.
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