Design Recommendations for Torlon Parts
Here are some of the important design recommendations for Torlon machining:
1. No Sharp internal Angles
At TOPS Precision, we recommend filleting all internal corners instead of using sharp angles, which tend to create internal stress concentrations. Rounded features not only enhance part durability but also minimize the risk of cracking during machining or end use—ensuring a stronger, more reliable component.
2. Add Thread Radii
When designing threaded features, incorporating rounded roots or small radii improves fatigue resistance and machining efficiency. This approach allows our team to use more accessible tooling, resulting in cleaner threads and reduced tool wear—especially critical for high-strength or precision-threaded parts.
3. Creep and Expansion
Although Torlon has low creep and thermal expansion, these factors must be considered for high-temperature or long-term applications. At TOPS Precision, we assist clients in specifying the correct tolerances during the design phase to ensure dimensional stability under thermal and mechanical stress.
4. Consider shrinkage after machining.
Torlon components often undergo post-machining treatments like annealing, which may cause minor dimensional changes. Our engineers work with clients to anticipate and compensate for shrinkage in tight-tolerance or interlocking parts—ensuring accuracy from design to final product.
5. Minimize Wall Thickness
For optimal results, avoid extremely thin or overly thick walls. At TOPS Precision, we recommend maintaining uniform wall thicknesses to balance strength, material efficiency, and machinability. This helps reduce warping, improves thermal consistency, and minimizes material waste.
Torlon CNC Machining Material of PAI
These are our most popular Torlon (P AI ) grades that we machine at TOPS Precision:
Torlon Grade | Key Attributes | Best Applications |
Torlon 4203 | Unfilled, high strength, excellent electrical insulation, low outgassing | Electrical insulators, vacuum parts, and semiconductor tools |
Torlon 4301 | PTFE + graphite filled; excellent wear resistance; low friction and creep | Bearings, bushings, wear pads, seals |
Torlon 5030 | 30% glass-filled; high rigidity; dimensional stability; high strength | Structural parts, load-bearing enclosures, and manifolds |
Torlon 5530 | 30% carbon-filled; electrically conductive; superior wear resistance | EMI shielding components, thrust washers, rollers |
Torlon 4435 | 10% PTFE + 10% graphite + 10% carbon fiber; improved tribological properties | Low-lubrication sliding applications, bearing cages |
Torlon 4275 | Slightly modified 4203; improved toughness and impact resistance | High-impact fixtures, mechanical guides |
Torlon AI-30 | 30% carbon fiber filled; highest modulus among grades; good conductivity | Aircraft structural fittings, high-load bearings |
Torlon 4540 | 40% glass-filled; extremely rigid and wear-resistant | Mechanical clamps, mounting |