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Polycarbonate CNC Machining Services

  • High-quality machines that are CNC and designed for thermoplastics assure neat and accurate cuts.
  • Crystal-clear parts are the result of using special tools and careful finishes in our production.
  • We have more than 10 years of experience using polycarbonate in machining without it cracking or melting.
  • TOPS provides services that can manufacture a single unit or thousands, depending on your project.

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    TOPS Precision focuses on cutting-edge machining of polycarbonate—a complex and clear thermoplastic. It has applications in many industries due to its qualities. For any job, from prototyping, fabrication de moules, or harsh environment parts to structural molding, the precision and smoothness of our CNC machines bring excellent results within close tolerances.

    Our machine parts made from polycarbonate are dependable and can be repeated in volume for aerospace and medical products. Our expert staff and the latest CNC machinery make sure your complex polycarbonate ideas become exact and useful parts.

    What Is Polycarbonate CNC Machining?

    What Is Polycarbonate CNC Machining?

    Polycarbonate CNC machining means using computer-operated tools to cut polycarbonate sheets, tiges, or blocks into the required shapes. Compared to injection molding, CNC machining can make fewer parts with high levels of accuracy and good detail. Since polycarbonate is easily affected by stress and heat, precision machining necessitates controlling the tooling speed, using very sharp tools, and applying advanced techniques to keep the surface and lenses clear.

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      How Does Polycarbonate CNC Machining Work?

      You begin by putting the CAD file together, and then do CAM programming to choose the most suitable tool paths for polycarbonate. Carbide-tipped tools, rapid speed, and low movement give us better results than melting the material. Liquid bar stock is used or air blown to help remove heat and decrease the wear on the tools. Correct clamping and fixing help lower stress inside the workpiece, which creates sharp edges, nice finishes, and strong parts, no matter how complicated the shape.

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        Different Methods to Process Polycarbonate in CNC Machining

        Here are the different CNC processes we can use for polycarbonate machining：

        Different Methods to Process Polycarbonate in CNC Machining

        Fraisage CNC

        Milling with a CNC machine is the usual way to produce complicated designs and features on polycarbonate. Rapid spindle speeds and sharp carbide tools are required to avoid the material from melting. Pour les meilleurs résultats, it is necessary to keep tool paths controlled and to remove all chips correctly.

        Tournage CNC

        CNC turning is especially suitable for making bushings and fittings from round polycarbonate. By rotating tools and following the right feed rates and speeds, thermal distortion can be prevented, and the finish becomes smooth without causing cracks.

        Routage CNC

        Using routing is most useful for machining polycarbonate sheets, as well as heavy and flat items. Routers that move quickly, when used with vacuum tables, allow for great stability and straight edge shapes. Pour la signalisation, panneaux, and enclosures that have to be cut along straight lines and with fine shapes, it is very useful.

        Forage CNC

        Drilling holes in polycarbonate requires being careful so that chips and cracks do not appear. For perfect results, choose a high-speed spindle, sharp bits, and reduce the feed rate. People often use peck drilling to decrease heat and get holes that are both smooth and clean.

        Découpe au laser (Only Occasionally Used)

        If used on thin polycarbonate sheets, laser cutting can help create well-defined or exciting designs. Toujours, when you use the iron, you have to be careful with the settings, as high heat may lead to color changes, bends, or burnt edges. When it comes to cutting structural components, mechanical methods are usually chosen.

        Débarquant et Polissage

        Généralement, Après l'usinage, flame or vapor polishing is used on polycarbonate parts to make their edges clearer. Manually removing burrs improves two aspects: the parts become safety-friendly and nicer to look at.

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          Properties of Machined Polycarbonate

          Here are some of the important properties we can opt for polycarbonate machining;

          Highly resistant to impacts

          Polycarbonate is very strong, stronger in fact than glass by up to 250 times. Pour cette raison, machine guards, safety covers, or enclosures in public places often use polycarbonate, since the material is good at resisting cracks caused by vibration or impact.

          Properties of Machined Polycarbonate

          Transparency

          Because its light transmission rate is 88–90%, machined polycarbonate still looks clear and glass-like. Due to its transparency, it works well in making lenses, fenêtre, and shields that should be clear and attractive.

          Stabilité dimensionnelle

          When the weather is hot or cold, polycarbonate remains the same size and shape. Because it has a slower rate of thermal expansion, parts in encasing and precision machinery will stay accurate throughout and over time.

          Résistance à la chaleur

          Polycarbonate is able to work nonstop even when the temperature reaches 120°C (248°F) without becoming deformed. Such resistance means it is right for use in hot places like lighting cases, electronic equipment, and vehicle parts.

          Isolation électrique

          Because of its superb dielectric strength, it is very good at preventing electrical current. That is why polycarbonate is commonly used as an electrical insulator, is found in circuit board parts, and serves as a shell for electronic devices.

          Poor Moisture Taking

          This resin doesn’t take in water and won’t be affected by changes in humidity levels. It is commonly found in outdoor, on the water, or medical settings where keeping moisture at bay matters a lot.

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            Polycarbonate Classifications and Key Properties

            Polycarbonate exists in various levels of quality and designs to suit specific needs like powerful performance, excellent clarity, flame resistance, or ease of machining. This table shows the most common types and what their main traits are:

            Polycarbonate Classifications and Key Properties

            Grade / Taper

            Principales fonctionnalités

            Applications

            Résistance à la chaleur (°C)

            Impact Strength

            Transparency

            General Purpose (GP)

            High clarity, balanced toughness, and stiffness

            Machine guards, lentilles, boîtiers

            Up to 120°C

            Very High – 250x stronger than glass

            ~90%

            Glass-Filled PC

            Increased rigidity and dimensional stability

            Pièces structurelles, logements, and load-bearing parts

            Up to 135°C

            Modéré

            Opaque

            Flame Retardant (FR)

            Meets UL 94 V-0 fire safety standards

            Électronique, panneaux, and electrical housings

            Up to 115°C

            Haut

            ~88%

            FDA-Approved PC

            Safe for food and medical use, good chemical resistance

            Récipients de nourriture, medical trays, and lab equipment

            Up to 120°C

            Haut

            Clair

            UV-Stabilized PC

            Improved resistance to yellowing and degradation under sunlight

            Outdoor panels, signage, greenhouse glazing

            Up to 120°C

            Haut

            ~88%

            Antistatic/ESD PC

            Designed to dissipate electrostatic charges

            Electronics manufacturing, cleanroom parts

            Up to 115°C

            Modéré

            Semi-transparent

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              Applications of CNC Machining for Polycarbonate

              Polycarbonate parts that are CNC-machined are employed in numerous industries.

              • Lenses and protection covers
              • Medical instruments and cases
              • Enclosures and panels in the aerospace field
              • Machine guards and safety shields
              • Lighting and dash in cars
              • Electronic components and insulators
              • Specially made enclosures, supports, and fixtures

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                Advantages of using Polycarbonate CNC Machining

                There are no expenses for tooling when you need only a small number of items.

                • Very accurate and having detailed surfaces
                • Allow the use of various design options for tricky or sensitive components.
                • It’s done much faster than the process of making parts by molding.
                • It can deal with both big and small sizes.
                • A design that is both clear and long-lasting in all areas
                Advantages of using Polycarbonate CNC Machining

                Common Challenges in Polycarbonate CNC Machining

                • Melting may occur if your candles are not cooled properly.
                • It can develop cracks along its edges when tools are not in good condition.
                • Poor clamping methods can result in your board warping.
                • Scratches noticed on the surface must be cared for after machining has finished.
                • Dust can collect on clean areas due to static buildup.

                Tips to Save Money on CNC Machining with Polycarbonate

                Here are some of the common tips that are crucial for saving money：

                • Simplify Geometries:Stay away from very narrow radii, deep spaces, or angles inside the part that need complicated tools or take a long time to shape.
                • Opt for Standard Stock Sizes:Go with common sizes for polycarbonate sheets or rods. Then there will be less waste, and you will spend less on purchasing.
                • Tolerances Guided by a Purpose: Applying tight tolerances should be limited to situations where it is required. Strict standards should be for important machine parts; the rest can be loose, so there is less time and expense spent on machines and inspection.
                • Avoid secondary processes:Include features that allow the parts to snap or self-align to make assembly and post-machining requirements smaller.
                • Purchase in Bulk:Reducing the steps of setting up the tools for each part reduces the cost for each product.

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                  Our Polycarbonate Machining Services are Guaranteed

                  We are confident in every product we make. All machining activities are carried out under ISO brand regulations, and the final step is careful inspection using CMMs, étriers, and image tools. What we do is backed by your satisfaction.

                  • High standards for quality and very precise measurements
                  • Share information openly at every step of the project
                  • Lead times that are quick and low prices
                  • Good help after you have implemented the product

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                    Choose TOPS Precision to Create Precise Polycarbonate Parts

                    Regardless of whether you need prototypes, tough housings, or strong mechanical parts, our team is all set to deliver them. We use the best CNC technology and know-how about polymers to supply polycarbonate parts according to your instructions, on your schedule, and within your budget. If you have files to send, do so, or talk to our engineers for assistance.

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                      FAQs About Polycarbonate CNC Machining

                      Oui, using vapor or flame polishing, CNC-machined polycarbonate can attain almost the same transparency as glass. D'autre part, polyurethane is both tougher and resistant to damage than acrylic.

                      T2: How thick can you machine parts with your machine?

                      Absolument. Polycarbonate is biocompatible, so it is popular in many types of medical products that do not go inside the body.

                      The standard tolerances are in the range of ±0.005″ to ±0.001″, but it depends on both the shape and size of the part.

                      Si nécessaire, we deliver extra services like bonding, fastening, and sub-assembly integration when requested.

                      Depending on the project’s details, lead time for polycarbonate usually lasts 5–10 business days.

                      Let's Start A New Project Today

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