For generations, New Process Fibre’s family-owned business has strived to provide ever-improving products and maximum quality while maintaining cost-effectiveness. As the business continues to grow and innovate, we are improving on processes and providing critical non-metallic stamping solutions to a variety of industries.
As New Process Fibre enters its third generation, our family’s desire to improve operations has only become stronger. As a one-stop shop for all of your plastic washer needs, our experts can provide Nylon, Teflon™PTFE, Polypropylene, Polyethylene, and many other types of plastic washers, all while remaining under one roof. You can learn more about New Process Fibre by checking out our new video.
Your Reliable Non-Metallic Manufacturer
New Process Fibre is an experienced custom manufacturer for a variety of top-quality non-metallic components. Since 1927, we’ve been at the forefront of non-metallic solutions. Ever since, we’ve been dedicated to delivering innovations designed to enhance quality while maintaining cost-effectiveness. We perform all of our operations under one roof in our Greenwood, Delaware campus, allowing us to keep a close eye on production quality throughout the entire manufacturing process.
By streamlining the supply chain, you can be assured that you’re doing business with a reliable partner. With a wide range of production equipment, raw material storage, an extensive material selection, and the ability to extrude our own plastics, we can meet any of your needs with a fast turnaround. We are proud to manufacture all of our products in America, and we’d love to work with you on your next project.
New Process Fibre: 1927 To the Present
Carl Porter started New Process Fibre in 1927 with a strong desire to enhance manufacturing processes. In fact, the company’s name is derived from the innovative process that Porter created for a new, more affordable way of transforming cotton paper into vulcanized fibre. With guidance from Porter’s son-in-law, Henry Peters, New Process Fibre moved towards enhancing all aspects of the non-metallic stamping process, which included vulcanized fiber washers.
Today, New Process Fibre continues to improve products, ensure optimal quality, and maintain cost-effectiveness. With a dedication to keeping all manufacturing operations in-house, we ensure that every aspect of the non-metallic stamping process meets the highest standards for quality. Our on-site capabilities include:
- Extruding our own thermoplastics
- In-house tool room with EDM capabilities, enabling us to make our own tooling
- A wide range of production equipment, allowing us to complete projects ranging from small prototype runs to multi-million piece production
As experts in non-metallic manufacturing, we are committed to delivering the highest level of quality to our customers. With a wide material selection and state-of-the-art tooling, we can create custom plastic washers in various colors, thicknesses, and diameters to meet a range of application requirements.
Our “Under One Roof” Philosophy
At New Process Fibre, we perform all of our operations in-house, which really sets us apart from the competitors. Specifically, we offer:
- Slitting and shearing. We can form sheets, strips, coils, and rolls from a wide range of non-metallic materials, including NEMA grade materials.
- Extrusion and slitting. We can extrude various non-metallic materials into coils, rolls, strips, and sheets in a range of dimensions.
- Tool and die making. Our superior tooling facilities allow us to create both basic and intricate tooling and dies using the latest technology to reduce overall cycle time.
- Non-metallic stamping services. With over 75 punch presses, more than 7,500 washer dies, and a range of colors and materials, New Process Fibre can create non-metallic parts to meet your specific needs.
For more information about our capabilities, or to work with us on your next non-metallic manufacturing project, contact New Process Fibre today.
Non-metallic stamping is the process of pressing a die through non-metallic material, such as thermoset, thermoplastics, or vulcanized fibre. Many industries are choosing this stamping process due to its ability to shape materials within tight tolerances and its cost-effectiveness. Non-metallic stamping produces parts such as plastic gaskets, fasteners, washers and much more.
The process of non-metallic stamping involves a high level of precision and attention to detail, which makes it imperative to use optimal machinery and have a team of highly experienced workers. To receive the best outcome, it’s essential to choose the right stamping provider for your needs.
Working with a manufacturer who can complete everything in-house comes with many benefits for the customer. A one-stop-shop that can deliver all required parts is much more convenient than working with multiple suppliers. One-stop-shop manufacturers optimize the design, production, and delivery processes of any manufacturing project. Some other key advantages of working with a one-stop-shop include:
- Quicker turnaround times: When you work with a single manufacturer, you gain the benefits of having a short supply chain, which includes reduced lead time. With everything being completed under one roof, the production process can move quickly through each stage, and there are no scheduling conflicts or long wait times to receive product shipments from multiple sources.
- Better communication: Custom manufacturing jobs can require special attention. Even a small issue can delay the entire project, so to get the best results, it’s important for everyone involved to have excellent communication. Partnering with a one-stop-shop means that everyone involved in your project can communicate directly with each other and resolve issues quickly.
- Lower costs: Having an in-house manufacturing process means that companies likely enjoy a lower price. One-stop-shops can offer cost-savings opportunities in many aspects of the manufacturing process, from packing, quality control, shipping, lead times, and more.
Various Portfolios of Non-Metallic Stamping Materials
Many significant developments have been made in metal stamping technology. These advancements have provided non-metallic alternatives to traditional metal stamping materials. Some of the most common non-metallic stamping materials that are used include:
- Vulcanized Fibre: This strong, lightweight material consists primarily of paper, wood pulp, and rag. In addition to being highly resistant to chemicals, solvents, and abrasion, it is also highly flexible, can withstand significant impacts, and has a high flammability rating. Vulcanized fibre performs well in high-stress environments and is available in grades such as commercial, electrical, bone fibre, trunk fibre, and wood laminating.
- Thermoplastics: Thermoplastics are non-metallic polymers that structurally change to become more gel-like when exposed to high temperatures or pressure. This allows them to be shaped into the desired part, and to be reshaped if desired. Thermoplastics can be manufactured quickly and consistently, with almost the same precision as metal components.
- Some of these at NPF include:
- Thermosets: Thermosets are a type of plastic that maintain their shape after the curing process and when exposed to high pressures and temperatures. This characteristic makes them ideal for high-heat applications such as printing systems, electrical component insulation, and general equipment insulation.
- Epoxy parts
- Custom Gaskets
Expert Quality Control and Production Management
Production management standards and quality control are two essential factors to take note of when choosing a non-metallic stamping provider. Having excellent quality control is vital to ensuring the customer receives products that are free from defects and will meet their needs. Additionally, having quality control practices in place makes a manufacturer less likely to deliver poorly made products or products that could be recalled. Many recalls could have been prevented with more effective quality control procedures.
It’s also imperative to consider the history of the manufacturer you are considering working with. Manufacturers with excellent production management track records are more likely to complete your project according to your specifications and on time.
When choosing the best non-metallic stamping provider, remember to consider factors such as experience and production capabilities. A manufacturer who can complete your project in-house can reduce delays and ensure easy communication so that your components arrive on time and on budget. Look for a manufacturer that can demonstrate clear quality control procedures as this is an important way to ensure you will get a final product that is free from any defects. If you’d like to learn more about the non-metallic stamping process, check out our eBook.
New Process Fibre is ISO certified and has been committed to delivering cost-effective in-house manufacturing services for over 90 years. To find out more about our non-metallic stamping services, please contact us, and to get started on your custom project, submit your request for a quote.
For many stamping projects, engineers are increasingly moving away from metal materials in favor of non-metallic options like fibres, laminates, and thermoplastics.
Exploring material options outside of metals can lead to enhanced performance and cost savings when creating stamped parts for particular applications.
A laminated plastic composed of cellulose, vulcanized fibre offers great electrical and mechanical properties. Lighter than aluminum, vulcanized fibre is stiffer than many thermoplastics and more resilient than leather. It’s almost 100 percent free of artificial binders, resins, or glues.
Offering resistance against impact, abrasion, organic solvent, petroleum derivative, and oil penetration, the material is light yet extremely strong. When used in a thinner format, vulcanized fibre offers flexibility with high tear and tensile strength, while thicker vulcanized fibre can be molded into distinct shapes using pressure and steam.
Vulcanized fibre is ideal for stamped parts used in the following applications:
- Automotive parts
- Electrical insulation
- Trunk fibre
- Bone fibre
- Wood laminating
An unclad material made of varying resin systems, some laminates utilize woven glass weave while others incorporate non-woven or none at all. Each type of laminate offers distinct electrical, chemical, and mechanical properties and is differentiated by the National Electrical Manufacturers Association (NEMA) into four grades: mechanical, electrical, machinable, and general purpose. Certain laminate grades are fire retardant.
Laminates are often employed for the creation of stamped parts for use in the petroleum, aerospace, electronics, and automotive industries.
Thermoplastics can be composed of various materials, including nylon 6, 6/6, acetal copolymer, polyethylene copolymer and homopolymer, and MDS. The use of thermoplastics allows for the creation of stamped parts in differing thicknesses with a high degree of accuracy as well as a uniform appearance. Thermoplastic stamped parts offer resistance from corrosion, wear, friction, and temperature.
Thermoplastics are often used for stamped parts in consumer products or across the aeronautics and aerospace industries.
The Importance of Material Selection
Skilled design engineers must consider factors such as heat, lubricant absorption, vibration dampening, and other performance impacts when selecting materials.
As examples, commodity thermoplastics perform poorly in electric motor applications as they are likely to melt on the armatures, and thermosets often crack or break when used in the wrong conditions. This doesn’t indicate ineffectiveness of plastics or mean that they are a risky material choice, but instead highlights the importance of material selection performance requirements to design engineers when developing parts and components.
Depending on your application, choosing the right non-metallic materials for your stamped parts offers significantly enhanced component performance. Download our eBook, Material Selection Guide, for a more in-depth look at the various materials available and the benefits of each in specific use cases.