TOPS Precision has a custom Bakelite machining facility suitable for industries where high thermal resistance, electrical insulation, and dimensional stability are required. We manufacture extremely precise Bakelite components that are used in electrical, mechanical, and structural applications by exploiting our expertise in thermoset materials and CNC machining technologies.
With a certified ISO 9001 facility, we produce low to large-volume runs, prototype development, and precision assembling. Whether the part you are manufacturing is switchboards, electrical insulators, or mechanical support parts, our team will ensure that every part is manufactured to your exact specifications with a high amount of repeatability.
These may include;
Bakelite phenol-formaldehyde thermosetting plastic is regarded as the first man-made polymer in the world. It belongs to the family of phenolics, which are hard, rigid, and non-conductive. After the curing process, bakelite is not a thermoplastic since it is irreversibly firm and can no longer be remodeled under heating.
Bakelite was created in the early 1900s. It was initially applied in radiotelephone casings and electrical insulators. Today, it is still a reliable industrial material used in processes that need thermal tolerance, size reliability, and even chemical resistance.
Bakelite is brittle and thermoset, which means that machining requires a well-controlled, high-speed, low-heat CNC process. Bakelite has the incapability of melting or reforming and must hence be shaped on brushes that are abrasive resistant, with appropriate feed speeds, and with the control of cooling.
Some of the important processes utilized are:
Vibration and temperature build-up tend to chip the surface or form internal micro-cracks, and are minimized during care. Our machining processes are individually optimized for brittle thermoset machining, such as Bakelite and Garolite, at TOPS.
Machined Bakelite combines the capabilities of physical, thermal, and dielectric properties, distinctively thereby presenting itself as a fine substitute for metal or soft plastics.
Its working temperature range of up to 300 degrees Celsius (572 degrees Fahrenheit), so it is ideal when there is a situation requiring exposure to heat. This heat resistance means that the component will not bend, soften, or corrode when exposed to high temperatures, such as those present in electrical, automotive, or even industrial environments.
A prominent feature of Bakelite is its high dielectric strength, which is in most cases about 200 V/mil. That is why it is ideal in insulators, circuit boards, and components of switchgear, where electrical isolation and safety are deeply emphasized.
When cured, Bakelite has structural rigidity and permanent shape, which is constant despite mechanical stress or changes in temperature. Such dimensional reliability is very important to precision assemblies as well as tight-tolerance parts.
Bakelite is an extremely hard thermoset product and registers M110120 on the Rockwell scale of hardness. Such a natural hardness makes the parts wear-resistant, avoids scratching the surfaces, and enables the durable performance of the parts in the moving assemblies.
Bakelite does not break down in typical chemicals, including oil, greases, alcohol, and mild acids. This is a reason why it can conveniently be used in the automotive system, in industrial plants, as well as in any other harsher environments where there are chances of encountering fluids or vapors.
The absorption of moisture is usually 1 percent or below, meaning that Bakelite retains its electrical and mechanical properties in wet or humid habitats. When exposed to water, it does not swell or soften and does not lose its insulating ability.
The following table shows a distinct difference between Bakellite, Phenolic, and Garolite G10.
Property | Bakelite (Phenolic PF) | Phenolic Laminates | Garolite G10 (Glass Epoxy) |
Base Material | Phenol + formaldehyde | Phenolic resin + paper/cotton | Epoxy resin + fiberglass cloth |
Mechanical Strength | Moderate | Moderate | High |
Electrical Insulation | Excellent | Very Good | Excellent |
Machinability | Good | Good | Difficult (abrasive) |
Moisture Resistance | Moderate | Moderate | High |
Temperature Limit | ~300°C | ~250°C | ~140°C |
Some components will need to be processed after coming out of Bakelite to fit a certain visual or dimensional criterion, even though in its natural form, the finish is smooth and matte. TOPS Precisions provides the following finishing services:
Bakelite finds much application in industries where non-conductivity, resistance to heat & stability are strong requirements.
Machining Bakelite presents an array of performance and cost advantages to OEMs, fabricators, and engineers:
In spite of its merits, Bakelite presents a special problem:
Brittle Nature – Fragile Nature; may fracture when fed wrongly or too much vibration is present.
Tool Wear – Abrasive filler present in the form of filler dulls tools fast.
Generation of Dust – Fine particles of dust have to be extracted and filtered.
No Reworking – After you cure, you can not remake it; it is essential that the first machining be done accurately.
Poor Impact Resistance – Not suitable where there is shock loading.
TOPS Precision has experience with these thermoset machines, however, and we know how to reduce those risks and produce quality parts.
All components are manufactured in our ISO 9001-certified system and are supplied with:
We support everything we make regarding Bakelite parts: as long as it has a purpose and is in line with regulations, your part will be good.
Whether it is consultation or delivery, TOPS Precision turns your ideas into manufacturable solutions through precision, repeatability, and performance. We provide:
No matter the quantity of prototypes or production parts you are in need of, TOPS Precision has you covered with the finest in Bakelite machining.
Yes. Although Bakelite is frail, most of us hold tolerances down as tight as 0.05mm plus or minus using our better tooling and setups.
To be stable, we suggest a minimum of 2mm Wall thickness; otherwise, they will crack during machining or use.
Absolutely. It is highly electrically insulating and as such finds constant application in electric spots.
We can quote and program in the following formats: STEP, IGES, DWG, DXF, and STL.
Yes. Part IDs, symbols, and serial numbers can also be laser-engraved on request.
It is resistant to a wide range of environmental influences, although it can degenerate under the influence of UV radiation. Extended time in the sun can result in the need for coating or sealing.