Hybrid Manufacturing Process Greatly Reduces Production Costs of CNC Machined Plastic Parts

Abstract

Abstract This paper is an introduction of a new hybrid plastics processing technology known as NNS (Near Net Shape) Technology, that demonstrates significant cost savings in the production of CNC (Computer Numerical Control) machined advanced engineering plastics parts by combining injection molding and CNC machining. The cost savings of NNS technology and the process is demonstrated with manufacturing examples comparing the traditional process of CNC machining parts from stock shapes such as sheet, rod or tube to the NNS technology process. Included in the examples are detailed production case histories with data supporting significant material cost savings and reduced machine time that are possible when NNS technology is utilized. NNS technology not only reduces the cost of producing CNC machined plastic parts but gives engineers the option to specify even higher performance plastics that can offer greater life in application. Plastics that offer improved chemical resistance, higher operating temp capabilities, and higher mechanical properties can now be specified that may have been cost prohibitive in the past with traditional CNC machining. NNS allows for initial lower part costs and more importantly lower cost-in-use with improved performance in the application. Common applications that can benefit from NNS include high performance plastic bearing and wear components, structural components, electrical insulating components and numerous other components across a wide range of oil and gas applications from onshore, downhole, offshore and subsea. Not all CNC plastic parts can benefit from NNS technology. We share the guidelines that we have found successfully help engineers to identify those parts that can benefit from NNS technology to reduce the production cost of CNC plastic machined parts for Oil & Gas applications.