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Dimensional Stability in Plastics: Key Factors and Materials

Nylon MDS washers black
If a material is dimensionally stable, it keeps its shape and exact dimensions throughout the manufacturing process and during use, even in adverse or extreme environmental conditions. This is an essential quality for plastic goods and components, which are susceptible to wear, cracks, melting, and deformation over time. By choosing dimensionally stable plastics in your manufacturing projects, you can guarantee a higher degree of precision and reliable performance throughout the lifespan of the final product or assembly.

Learn more about the different factors that can impact the dimensional stability of polymers, so you can choose the right engineering plastics for your application.

Factors Affecting Dimensional Stability

Moisture, temperature, and mechanical stress are three of the biggest factors that can affect the dimensional stability of different plastics. However, by examining the degree to which these factors impact specific plastics, you can choose the most reliable substrates for your products or applications.

Moisture and Humidity

Most plastics will absorb some degree of moisture from their environment, but different plastics absorb different amounts of moisture at varying speeds. Over time, this moisture can affect the plastic’s mechanical strength, electrical properties (such as dielectric loss factor), and physical dimensions.

For example, polyamides, or nylon plastics, are very absorbent compared to other plastics. After assembly in a final product, the nylon component can absorb water that changes the component’s shape, insulative properties, and mechanical strength. However, polytetrafluoroethylene (PTFE) products are unique because they don’t absorb any water, making PTFE the preferred plastic for goods that will be used in wet or humid environments.

The following low-absorption plastics are also popular choices for plastic components that need to retain stable characteristics long-term:

These plastics do absorb some degree of moisture, but they still perform consistently in moist, high-temperature conditions. For best results, they need to be manufactured in extremely low-moisture conditions and thoroughly dried.

Temperature

Temperature can also significantly impact dimensional stability, as both high and low temperatures can make some plastics expand or contract, respectively. Compared to metals, plastics have higher thermal expansion coefficients and thus change more in size in response to heat. So, for complex or tightly-packed configurations that will operate in extremely low-temperature or high-temperature environments, select plastics with low thermal expansion coefficients.

Some popular plastics for use in extreme environments include:

  • Polyetheretherketone (PEEK): This plastic offers relatively high thermal stability in hot environments.
  • Polytetrafluoroethylene (PTFE): This plastic also offers relatively high thermal stability, even at high temperatures.
  • Polyamide-imide (PAI): This engineering polymer has excellent stability and reliable mechanical characteristics at high temperatures.
  • Polyetherimide (PEI): This is another popular engineering polymer with similar characteristics to PAI.

In addition to choosing the right base polymers, manufacturers can add reinforcing fibers to the plastics during initial fabrication. This fiber can help the plastic substrate hold its shape and retain its mechanical strength amid temperature fluctuations. When done properly, fiber-reinforced plastics have similar thermal expansion coefficients to aluminum. As a result, these plastics can be reliably used in configurations alongside metal components without becoming misaligned.

Mechanical Stress

The third important factor to consider is mechanical stress. Compression, wear, and other forms of stress can make plastics distort over time, both while the pressure is being exerted and even afterward, meaning the plastic won’t bounce back to its original form. Dimensionally stable plastics can withstand a high degree of mechanical stress without changing shape.

As a general rule, stiffer plastics like PEEK, PPS, and PAI are more resilient and able to withstand short-term mechanical stress due to having high tensile strength and compression strength. They can also withstand longer-term stresses like creep, which is the propensity of some materials to permanently deform over time due to pressure. Ideally, manufacturers should select no-creep or low-creep plastics for long-term applications.

Material scientists are continuously developing and testing new plastic polymers to understand their short-term and long-term responses to mechanical stress.

Choose Dimensionally Stable Plastics From New Process Fibre

At New Process Fibre, we specialize in developing non-metal products with excellent dimensional stability for a wide range of industrial applications. Since 1927, we have produced gaskets, shims, spacers, washers, and other non-metal goods that need to perform reliably in high-pressure and high-temperature environments.

We help our clients select from LDPE, HDPE, Teflon PTFE, PEEK, and other specialty plastics to create the right products for their diverse needs. Our comprehensive fabrication, stamping, die-making, extrusion, and quality control services make it easier than ever to have high-quality plastic goods that can stand up to extreme industrial conditions. Contact us today to learn more about our non-metallic stamping capabilities for dimensionally stable plastics.

Nylatron® vs. Nylon MDS

Depending on the application, nylon MDS or Nylatron® may be an ideal material. Learn more about their chemical, physical, and mechanical properties, as well as their common applications, to decide which material is best for your project.

Chemical and Physical Properties

Nylatron® is a type of nylon filled with molybdenum disulfide (MoS2), which is a synthetic lubricant compound that improves the nylon’s ability to handle loads and resist wear without compromising its strength.

Nylon MDS is an extruded nylon 6/6 material containing molybdenum disulfide. The MDS particles enhance wear resistance and surface lubrication. 

Both of these materials are forms of nylon enhanced with MoS2 to improve their wear properties and longevity. Unlike nylon MDS, Nylatron® comes in multiple grades designed with added properties, including load bearing, self-lubrication, and wear resistance characteristics.

Mechanical Properties

Nylon MDS washers black

Nylon MDS and Nylatron® both offer certain improved mechanical properties compared to traditional nylon. Their MoS2 content improves their wear resistance, surface lubricity, and durability.In particular, Nylatron® offers:

  • Superior fatigue resistance
  • High mechanical toughness, strength, hardness, and stiffness
  • High resistance to wear
  • The highest level of wear resistance of all thermoplastic materials (Nylatron® NSM)

Nylatron® and nylon MDS both benefit from increased durability and strength, but the multiple grades available with Nylatron® make it better for more specialized applications. However, in general, nylon MDS offers high flexural and tensile strength comparable to that of Nylatron®. Both materials have similar characteristics that make them good choices for load-bearing and/or friction applications.

Applications and Uses

Some popular uses for Nylatron® include the following:

  • Bearings, gears, sheaves, and sprockets: Nylatron® GMS PA6, a Type 6 nylon, is a grade of Nylatron® typically used in these high-wear applications thanks to the material’s rigidity and strength.
  • Industrial wear pads and bearings: These applications often use the Nylatron® grade called Nylatron® LIG PA6, which features internal lubrication for increased toughness and strength.
  • Heavy load lifting: Larger-sized gears, bearings, and other heavy load-lifting components commonly use Nylatron® NSM. 
  • Food contact parts: Food processing applications require materials that are safe to come into contact with food or beverages. Nylatron® MC 907 PA6 is ideal for these applications, as this Nylatron® grade is 3A-Dairy compliant and FDA- and USDA-approved.

Some common applications for nylon MDS include:

  • Applications requiring high lubricity: If an application needs superior surface lubricity, it may use nylon MDS.
  • Nonmetallic washers in industrial equipment: Nylon MDS washers are an ideal alternative to metallic washers in industrial machinery components, which need optimized impact resistance and load-bearing capacity. 

Suitability for Different Industries

Nylatron® and nylon MDS offer collective benefits for diverse applications, such as:

  • Aerospace, appliances, automotive, plumbing, marine, and other industries: Many applications across these critical industries rely on MDS-filled nylon and Nylatron® because of these materials’ wear resistance, strength, and versatility.
  • Food processing: Applications requiring materials that are safe to come into contact with food often use compliant grades of Nylatron®.
  • Industrial applications: Nylatron®’s improved wear resistance, surface lubricity, and mechanical properties make it a dependable replacement for metal in many applications with heavy or large loads.

Contact the Experts at New Process Fibre

Nylatron® and nylon MDS both offer advantages that applications may need compared to traditional unfilled nylon. For more versatility, you could use different grades of Nylatron®, while other applications may use MDS-filled nylon for its increased wear resistance and durability. New Process Fibre is a leading custom fabrication provider for nonmetallic materials, including nylon 6/6, Nylatron®, nylon MDS, and more. We can help you determine the right material and product for your project. To get started, contact us today.

What Are Nylon Spacers and What Are They Used For?

Nylon spacers are a critical yet often overlooked component across diverse industries. Used to lengthen the space between connected parts, nylon spacers function as glides, bearings, bushings, and rollers. The highly durable features of nylon make these spacers resistant to cracks and corrosion, ideal for insulating against moisture and electricity. As a result, nylon spacers can be used across many outdoor and indoor applications in the electronics, construction, automotive, and other industries.

Learn more about nylon spacers, including their benefits in various applications.

What Are Nylon Spacers?

Nylon spacers are tubular components that create and maintain space between fastened parts. They ensure that each part is properly positioned or aligned within its assembly. Nylon is a versatile synthetic material that is strong, durable, non-flammable, chemical-resistant, non-toxic, and weather-resistant. These properties, along with the lightweight and non-conductive nature of nylon spacers, make them ideal for indoor and outdoor use across a variety of applications.

Applications of Nylon Spacers

Nylon spacers are used to create a specific distance between two objects. They also provide additional functions such as thermal insulation, electrical isolation, noise and vibration reduction, and supporting weight and pressure.

The lightweight and corrosion-resistant properties of nylon spacers make them useful for a variety of industries, including:

  • Construction
  • Manufacturing
  • Security
  • Electronics
  • Electrical
  • Automotive
  • Marine
  • Military
  • HVAC

Advantages of Using Nylon Spacers

Metal spacers made of brass, aluminum, or steel are common alternatives to nylon spacers. However, nylon spacers are preferable in many applications, due to the following distinct advantages:

  • Corrosion resistance: Since nylon doesn’t corrode like metal, it’s likely to last longer in marine and outdoor environments.
  • Lightweight: Nylon spacers have an excellent strength-to-weight ratio, which allows them to be used in weight-sensitive applications.
  • Chemical resistance: Compared to metals, nylon is more resistant to certain chemicals, including acids, alkalis, and organic solvents.
  • Resistance to UV radiation: Nylon spacers are generally more resistant to damage from sunlight and UV radiation than metal spacers.
  • Versatility: Nylon can easily be molded into various shapes and sizes, making it ideal for customization.
  • Electrical insulation: Nylon’s non-conductive properties prevent the unwanted transfer of electricity between components.
  • Low cost: Nylon spacers are usually less expensive than metal spacers.
  • Temperature: Nylon has characteristics to protect against extreme temperatures- both hot and cold.

Custom Nylon Spacers from New Process Fibre

Nylon spacers are crucial for the precise positioning of components in machinery and assemblies in many industries. Their strength, resistance to chemicals and moisture, and electrical insulation properties make them ideal for use in many environments where metal isn’t a feasible option.

All nylon products from New Process Fibre meet LP-410 Standards, ensuring our spacers deliver the quality necessary to meet your project requirements, whether you need custom spacers, gaskets, washers, insulators, or other shapes. We’ve been meeting the needs of our customers with custom fabrication solutions since 1927.

With state-of-the-art tooling and a wealth of experience, New Process Fibre produces a variety of custom nylon parts to serve a wide range of industrial applications. Contact us for more information about our custom nylon spacer capabilities.

What Is Lexan/Polycarbonate, and What Are Its Applications?

What Is Lexan Plastic?

Lexan is a brand name for polycarbonate, a plastic popular for its flexibility and durability. The brand name was created by General Electric (GE) in 1953, pioneering the development and production of the material in the U.S. Lexan’s unique chemical structure and fabrication process make it durable enough to be bulletproof but flexible enough to create delicate components. These versatile qualities have led manufacturers to utilize polycarbonate in a wide variety of modern products and parts.

Learn more about the benefits, limitations, and applications of Lexan to see if it’s the right material for your application.

Benefits of Lexan / Polycarbonate

Lexan is a strong thermoplastic that offers 30 times more impact strength than acrylic—another thermoplastic—and 250 times more impact strength than glass. Polycarbonate is ideal for applications where strength and protection are a priority. Here are some of its other benefits:

  • Low rigidity (available in flexible grades)
  • Withstands high temperatures (up to 240 °F) without deforming
  • Resistant to harsh chemicals like acids and gasoline
  • Can be drilled without the risk of cracking or shattering
  • Cold formability
  • Low flammability
  • High strength-to-weight ratio
  • Optical clarity similar to glass
  • Does not degrade in the presence of pressure-sensitive chemicals
  • Considered an eco-friendly material

Limitations of Lexan / Polycarbonate

With the degree of flexibility and strength Lexan offers, users should also be aware of the material’s inherent limitations:

  • More prone to scratches than glass and other thermoplastics
  • More expensive compared to glass and other thermoplastics
  • UV rays may cause yellowing over time
  • Easily dented

Examples of Lexan Products

If the goal is to create a highly protective material with less concern for aesthetics, Lexan is an excellent material.

Here are just some products that use Lexan:lexan-examples

  • Electrical components
  • Site glass in piping and machinery
  • Tablets, computers, and phone cases
  • Window well covers
  • LED light diffusers and pipes
  • Face visors and shields
  • Machinery guards
  • Automobile components like cluster panels
  • Flashlight lenses

Applications of Lexan

Many industries rely on Lexan to create a variety of components and products. Here are some of the most popular examples:

  • Aerospace/Automotive: Lexan makes durable, lightweight windshields for automobiles, aircraft, and trains. It’s also used to build isolation walls for bank counters and bullet-resistant automobile windows.
  • Defense: The material is lightweight and has high tensile strength, making it ideal for building parts for military jet fighters and vehicles. Lexan is also used to make lightweight accessories for soldiers, lightening the loads they carry.
  • Electronics Technology: Lexan is used to manufacture electronic components since it offers good insulation against electricity and resists corrosive chemicals and heat. Polycarbonate goes into screens for computers and televisions, as well as CDs and DVDs. The material is also commonly used for making video game controllers and cell phone cases.
  • Eco-friendly Products: Lexan is highly recyclable, making it ideal for manufacturing eco-conscious products. These include food containers, water bottles, canteens and glasses. Lexan is a superior alternative to glass in these applications because it resists fractures while maintaining transparency.

Lexan vs. Acrylic

Acrylic’s trade name is Plexiglas, trademarked by Rohm and Hass. Its generic name is plexiglass, and other trade names include Acrylite and Lucite. Lexan and acrylic are similar thermoplastics commonly used as alternatives to glass, but they weigh half as much and are much more shatter-resistant than glass. Both materials are transparent, see-through plastics that have similar flexural strengths and are easy to clean.

Compared to Lexan, acrylic offers more light transmission, clarity, and shine. Additionally, acrylic is more resistant to scratches, UV light, and yellowing. However, protective coatings can help Lexan resist scratching. While Lexan can be formed in cold temperatures or bent without heating, acrylic can only be bent when heat is applied.

Lexan costs about 35% more than acrylic on average, but the extra cost can be justified by the unmatched impact resistance and durability Lexan offers.

Lexan/Polycarbonate and Other Non-Metallic Products From New Process Fibre

Lexan’s material properties make it a versatile plastic with extensive capabilities. Its impact resistance, durability, and lightweight properties are its main advantages over other plastics.

New Process Fibre Company is a top supplier of industrial non-metallic parts to manufacturers in various industries. We have years of fabrication experience processing thermoplastic materials like Lexan. Browse our product catalog, or contact us today to consult on your Lexan material needs. We can also advise you on appropriate materials for your non-metallic components.

What Is Nylatron®?

Since 1927, New Process Fibre has been a leading provider of high-quality commercial and industrial components. Our versatile facility allows for prototyping and small- and large-volume production runs of products made with a diverse array of thermoplastics, including Nylon 6, Nylon 6/6, Nylon MDS, and Nylatron® material.

What Is Nylatron®?

Nylatron® is the name given to a group of nylon plastics usually filled with molybdenum disulfide lubricant powder. Different types of Nylatron® material offer different strengths and characteristics to meet the needs of a variety of applications, which include the following:

  • Washers
  • Bearings
  • Rollers, Wheels, and Wear Components
  • Wear Pads
  • Gears
  • Nozzles
  • Actuators
  • And morenylatron-washers

Properties of Nylatron®

In general, Nylatron® material is highly machinable and prized for these properties:

  • Mechanical strength
  • Good stiffness, hardness, and toughness
  • Good machinability
  • High mechanical damping ability
  • Fatigue and wear resistance
  • Good sliding properties
  • Effective electrical insulating characteristics
  • Resistance to high energy radiation (gamma- and X-rays)

Certain types of Nylatron® have been specifically engineered to provide enhanced load-bearing capabilities, rigidity, and other characteristics to meet the demands of specific applications.

Types of Nylatron®

There are numerous types of Nylatron® material, and the one you choose will depend largely on the desired characteristics of your finished product and the demands of its application. These are three of the most popular:

  • Nylatron® GS: Enhances strength and rigidity. Its lower thermal expansion ensures better fit, reduced seizing in bearings, and improved clearances compared to Nylon 101.
  • Nylatron® GSM: Maintains the impact resistance you’d expect from Nylon 6, but it has increased load-bearing capabilities.
  • Nylatron® NSM: Made for the most demanding high-velocity applications, Nylatron® NSM is used for large components like gears, bearings, and wear pads. With superior wear resistance and self-lubricating additives, it offers a lifespan of up to 10 times longer than standard Type 6 Nylon.

Nylatron® GS and Nylatron® GSM: Differences and Similarities

These two common Nylatron® materials have many of the same applications and offer similar benefits. Take note of the primary differences:

Nylatron® GS

Nylatron® GS is filled with molybdenum disulfide (MoS2) and engineered to be stiffer, harder, and more dimensionally stable. As a result, it loses some of its impact resistance. With a coefficient of linear thermal expansion lower than Nylon 101, components made of Nylatron® GS maintain a better fit and are less likely to seize. With a tensile strength of 12,500 psi and compressive strength of 16,000 psi, Nylatron® GS is commonly used for pulleys, gears, bearings, sheaves, valve seals, and more. It has a temperature range of -20°C to +95°C (-20°C to +70°C in water).

Nylatron® GSM

This gray-black material includes finely divided MoS2 particles for enhanced load-bearing capabilities. Like nylon, it has excellent impact resistance and is known for its toughness and abrasion resistance. With a compressive strength of 14,000 psi, Nylatron® GSM is a popular choice for bearings, cams, forming dies, insulators, rollers, wear plates, wheels, and more. It has a temperature range of -30°C to +105°C (-30°C to +70°C in water).

At New Process Fibre, we provide Nylatron® GS in rods and sheets, cut according to your requirements. Download our datasheet to learn more.

Alternatives to Nylatron®

We highly recommend Nylon MDS as the best alternative to Nylatron®. On a molecular level, these materials are the same, giving you the same high-level performance without the high-level price tag associated with the brand name. Nylon MDS is also more readily available than Nylatron®, allowing for a quicker turnaround to save you time and money.

New Process Fibre offers both Nylatron® and Nylon MDS, and we will work with you to decide which one is best for your application based on your budget, preferences, and component requirements.

Nylon MDS and More From New Process Fibre

New Process Fibre provides custom fabrication services using a wide range of materials, and our knowledgeable team will help you determine which material is best for your needs. We offer in-house thermoplastic extrusions, in-house tooling, custom washer design, and so much more. Take a closer look at our catalog to learn more about what we can do for you, then contact us to get started on your project using Nylon MDS, Nylatron® material, or another thermoplastic.

The Differences Between Nylon 6, Nylon 6/6, and Nylon MDS

When it comes to producing nonmetallic stamped components, manufacturers have several material options to choose from. Nylon is often a popular choice due to its versatility and various other beneficial properties. Because nylon is available in several product variations, it is well-suited for use in a wide range of industries and applications, including plumbing, automotive, household appliances, machinery components, and many more. Here, we’ll discuss the primary differences between Nylon 6, Nylon 6/6, and Nylon MDS to help you decide which option is best for your needs.

The differences between Nylon 6, Nylon 6/6, and Nylon MDS

What is Nylon 6?

Nylon 6 features a slightly lower continuous service temperature rating than Nylon 6/6 but can withstand higher speeds and loads when used in bearing applications. This material has all of the primary properties of any nylon polymer, including toughness, stiffness, good insulation characteristics, and excellent mechanical dampening.

Nylon 6 is often found in fabrics but is also a suitable replacement for steel, aluminum, brass, and other metals. Its high strength combined with its other desirable properties make it a great choice for applications such as:

  • Spacers
  • Washers
  • Gears
  • Plumbing parts
  • Bearings
  • Insulators
  • Forming dies
  • And much more

What is Nylon 6/6?

Nylon 6/6 is similar to Nylon 6 but features a few key distinguishing features:

  • Chemical resistance. Compared to Nylon 6, Nylon 6/6 is more resistant to acids, making it a better option for applications exposed to harsh chemicals.
  • Higher service temperature range. Continuous service temperature range refers to the highest temperature a material can withstand before permanent degradation occurs with prolonged exposure. While Nylon 6 has a continuous service temperature range of 200°F, Nylon 6/6’s continuous service temperature range is 210°F.

These features make Nylon 6/6 suitable for applications such as steering parts, chemical components, electrical components, plumbing parts, and more.

What is Nylon MDS?

Nylon MDS is a variation of Nylon 6/6 made with fine MDS particles. The addition of MDS enhances the load-bearing capacity of the material without sacrificing its impact resistance. MDS-filled nylon also has self-lubrication qualities comparable to PTFE, resulting in exceptionally high service life and resistance to wear.

In addition to its cost-effectiveness, Nylon MDS features superior durability and toughness, making it a great material choice for components exposed to high mechanical stresses. As the strongest and hardest form of nylon, it is ideal for applications such as washers for machinery components, parts that are in constant motion, boating and marine parts, kitchen appliances, food-grade applications, bearings, gears, and more.

How to Select the Correct Type of Nylon for Your Application

When choosing between Nylon 6, Nylon 6/6, or Nylon MDS, you must consider your application’s specific requirements for processing, mechanical properties, and aesthetic appearance:

  • Nylon 6. Nylon 6 is ideal for applications requiring a lightweight material with high stress and impact resistance. Due to its lustrous finish, it has a more attractive appearance than Nylon 6/6. However, this material is not ideal for applications exposed to high-temperature water, as it has a lower heat deflection and higher water absorption rate. For these instances, Nylon 6/6 would be the superior choice.
  • Nylon 6/6. Nylon 6/6 is the best choice for applications requiring a high-performance engineering plastic capable of withstanding higher temperatures. It also offers good stiffness, tensile strength, and flexural modulus, making it suitable for repeated long-term use.
  • Nylon MDS. Finely divided particles of MDS impart extra lubricity to this type of Nylon, allowing it to function with little to no lubrication. This makes it ideal for applications where external lubrication is contaminating, difficult to maintain, or impractical. The extra lubricity also enhances component lifespan, making Nylon MDS a cost-effective option.

High-Precision Nonmetal Stamping Services From NPF

Selecting the right nylon is key to ensuring the success of your nonmetal stamping project. At New Process Fibre, we are well-equipped to handle standard and custom nonmetal stamping projects of any size. Whether you choose Nylon 6, Nylon 6/6, or Nylon MDS, we can work with you to create high-quality stamped parts that fit the needs of your application. To learn more about our precision nonmetal stamping capabilities, or for help determining which nylon material is right for your needs, contact us today.

Trends in Reshoring

As a family business, we place a special emphasis on providing clients with fully in-house solutions. Since 1927, New Process Fibre has served American markets with unmatched quality and cost advantages facilitated by cutting-edge tooling equipment, thorough industry knowledge, and razor-sharp quality controls.

Today, U.S. reshoring efforts have sparked massive demand for non-metallic parts stamping services, as overseas enterprises bring entire operations back home. It’s become a major test of a company’s organizational and parts management efficiencies, supplier relationships, and overall agility. We’re helping them overcome these challenges by mending broken supply chain links with American-made non-metallic stamped parts from our centrally located East Coast headquarters.

Latest Trends in U.S. Reshoring

Trends in Reshoring

What is reshoring, and what effect will it have on domestic manufacturing?

Reshoring is essentially the opposite of offshoring — when companies largely expatriated in pursuit of lower operating costs. Now, non-domestic overseas operations are facing counter-pressure to repatriate to their country of origin.

Driving these trends is a critical mass of corporate and government bodies focusing on the risks posed by offshoring, including supply chain breakdowns and the nationwide threat of disease. Overseas manufacturers are on the front lines of these and other challenges, prompting industry leaders to take a closer look at the benefits of reshoring.

An overwhelming 92% of CEOs surveyed in the Kearney 2021 Reshoring Index have expressed favorable opinions of reshoring, while 79% of U.S. executives running operations in China have either already begun reshoring operations or plan to within the next three years.

To facilitate these massive readjustments, manufacturers are turning to Advanced Planning and Scheduling (APS) software to maintain a broad view of operational needs. When integrated with Material Requirements Planning (MRP) and Enterprise Resource Planning (ERP) software, APS helps reshoring planners maintain agility while accommodating new priorities, inventory movement, and production schedules.

The result is greater scheduling flexibility and enhanced operational efficiency and accuracy. APS and ERP/MRP integrations also help industries meet consumer demand for quick deliveries and higher product assortments without succumbing to downward cost pressures.

Benefits of Reshoring and American-Made Manufacturing

The benefits of reshoring have been known for a long time, but modern geopolitical pressures might be precipitating a lasting change toward robust domestic manufacturing practices. Companies and their home countries all stand to gain from the benefits of reshoring, such as:

  • Improved Product Quality: Reshoring gives manufacturers renewed control over their production process. Because it invokes stricter regulatory standards, manufacturers must also produce higher-quality products.
  • Competitive Advantages: When available, consumers overwhelmingly prefer products made in America. A study from Perception Research Services recently confirmed that consumers gravitate to products with “Made Locally” labels, giving fully reshored companies an edge in their domestic market(s).
  • Lower Risk: Domestic production simplifies and shortens supply chains. It also makes many shipping and customs steps obsolete, and companies achieve more direct involvement in each stage of production.
  • Time Zone Alignment: Reshoring puts geographically dispersed organizations back into alignment, making it easier to coordinate production and business functions. By reducing time zone coordination issues, collaboration improves and manufacturers experience fewer disruptions.

NPF is Proud to Partner with Companies Reshoring their Manufacturing to the U.S.

NPF’s Delaware campus is strategically located on the central East Coast, where we maintain our non-metal stamping services all under one roof. Like reshoring, keeping all operational needs readily available gives us greater control over quality, reducing production costs for our clients in the process.

Our capacities are available to manufacturing companies of any scale, and our one-time tooling process, fast turnarounds, and nationwide distribution make us an attractive resource for offshore companies looking to reshore. NPF is dedicated to supplying custom non-metallic stamped parts fully made in America. We also take strides to secure raw materials free of conflict minerals, which further benefits domestic markets.

Facilitating the Return of American Manufacturing

Just as companies seek greater self-integration, NPF knows the value of maintaining operations all under one roof. It allows us to move with greater speed while tightening every stage of operations. To learn more about our high-quality precision-stamped parts or to book a consultation, contact us and tell our experienced stamping technicians about your reshoring needs.

When Nylon Washers Are Your Best Choice

Nylon washers are one of the most frequently used types of hardware for industrial design purposes. They’re critical components of threaded fasteners and make a highly cost-effective alternative to metal washers. It’s because nylon is made of a synthetic polymer, called polyamide, that’s much more affordable and easy to fabricate. We’ll explain the benefits of nylon, what nylon washers are used for, and how to select exactly the right nylon washer for your application.

Features of Nylon Washers

Nylon Washers

Unlike metal alternatives, nylon washers are adaptable to a wider range of applications. They’re essentially small pieces of hardware, usually of a flat ring shape, though they can be made in virtually any shape and color. In addition to flat ring washers, there are also square, half-moon, quarter-moon, and many other shapes. Nylon washers are most often used to seal components, separate hardware, and distribute the load forces exerted by threaded fasteners.

New Process Fibre is fully equipped to design and fabricate any type of nylon washer according to the exact specifications of our clients. Depending on the nylon washer’s purpose, our nylon fabrication and stamping specialists can provide fast quotes for washers of any size, shape, thickness, and material considerations.

Benefits of Nylon Washers

Due to nylon’s unique balance of qualities, nylon washers are a highly effective and versatile choice for numerous industries. The main benefits of nylon include the following:

  • Lightweight
  • Durability
  • Chemical, rust and mold resistance
  • Absorptive properties for both vibration and noise
  • Compressible into effective mechanical seals
  • Low surface friction, facilitating easy movement between materials (which slows deterioration)
  • Electrical and thermal Insulation
  • Cost-effectiveness

Because nylon washers are lighter than metal, they’re also cheaper to ship and can boost the fuel economy of automobiles, aircraft, and other vehicles requiring high quantities of washers.

Nylon Washers Considerations

What are nylon washers used for? With nylon’s extensive material benefits, virtually every industry relies on nylon washers. Generally, they’re frequently used wherever a design requires mechanical spacing or load distribution between hardware when metal is ineffective due to corrosion, weight, or other limitations. There are numerous factors to consider when deciding when to use nylon washers in your project.

Dimensions are a primary consideration, including thickness. This raises the question of function: will your nylon insulate or seal components, space hardware apart, or distribute forces exerted by fasteners? For example, thicker nylon washers are more durable and absorptive than thinner alternatives, but they take up more space and may be less compressible.

Shape is another consideration. Options besides flat rings can be useful in uniquely shaped recesses or when only one-half of a fastener is accessible. In the latter case, moon-shaped nylon washers are appropriate. The right type of nylon is also important, and there are several types of nylon with unique mechanical, chemical, and other properties.

Certain polymers, such as Nylon 6, have higher impact resistance and load-bearing capacity than standard nylon. Nylon 6/6, a more crystalline type of Nylon 6, is even stronger, with greater thermal insulation and less water absorption.

Our nylon fabrication experts can work closely with you to select the right combination of form factors and material considerations to most effectively achieve your design requirements.

Why Choose New Process Fibre

The wide-ranging benefits of nylon make it a highly versatile and often more effective alternative to metal washers, especially when corrosion resistance, weight, and costs are significant design factors. New Process Fibre has nearly a century of experience in nylon and other non-metal stamping services. In that time, our family-run business has accumulated a long track record of consistent innovation in nylon fabrication methods and technologies.

We continue that tradition, finding new ways to advance our clients’ interests at our state-of-the-art facility. For any questions or to inform us of your non-metal custom fabrication needs, contact us. Our experienced nylon stamping experts will help select the right nylon washers or work with your product developers to create a new custom washer solution according to your exact specifications.

An Overview of New Process Fibre

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.

An Overview of New Process Fibre

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. 

Working with New Process Fibre: Tooling & Machinery

As an ISO 9001:2015 registered manufacturer, New Process Fibre offers superior quality tool and die manufacturing and nonmetallic stamping services custom-designed for specialized requirements. Learn more about our state-of-the-art tooling and machinery as well as the benefits of partnering with us for your tooling and nonmetallic stamping needs.

State-of-the-Art Tooling

With our advanced tooling and technology, we can efficiently perform all services, reducing production cycle times and adhering to stringent tolerances. We can accommodate our customers’ diverse design requirements using the following capabilities:

  • 75 conventional and high-speed punch press machines
  • More than 10,000 compound washer dies
  • Vast material inventory
  • Free maintenance of your tool for the full duration of your program, with only a partial tooling charge
  • CAD/CAM
  • Progressive and compound dies
  • Custom die design and manufacturing
  • Multi-cavity tools that save material costs and increase throughput
  • Cost-effective and critical tolerance applications
  • Wire EDM capabilities
    • Automated wire EDM cutting can remove excess material without leaving damage or residual stress on the workpiece. It’s also ideally suited for hard, difficult-to-machine materials, reducing the need for secondary treatments. For the manufacturing sector, wire EDM often creates dies and molds, especially blanking punches and extrusion dies. The process can accommodate prototypes or large production runs of aerospace, automotive, and electronics components that have minimal residual stress.

Cutting-Edge Machinery

At New Process Fibre, we furnish our facilities with premium specialty equipment so that we can fulfill high-volume, high-speed orders of complex projects. Our two main types of equipment are Bruderer stamping press machines and Euromac CNC punching machines.

Bruderer Stamping Press Machines

Bruderer stamping press machines produce high precision, accuracy, and speed even when working with difficult materials or complicated designs for large volume runs. The machines feature responsive clutch and brake units that enable small changes and fine-tuning. Their first-punch accuracy means we can consistently ensure the quality and repeatability of the finished products. We keep our machinery well-calibrated and maintained to deliver optimal performance every time.

Euromac CNC Punching Machines

Euromac CNC punching machine These highly productive machines incur low running costs. Their larger working surfaces provide greater stability while punching parts out of flat sheets. This machine is particularly well-suited for low volume runs and producing prototypes.

Benefits of Working with New Process Fibre 

We continually improve our equipment to be the most up-to-date so that our customers receive the highest quality products on time. Some of these products can be punched without making a new tool, further reducing your production costs and turnaround times. Our machines are also dedicated to specific materials, such as sheet material, canvas, and G-10, ensuring the best quality for your nonmetallic products.

All hard tooling is developed in our in-house tool shop, which allows us to machine parts to tighter tolerances. Our niche method of developing tooling for customers means that you only pay a one-time tooling cost regardless of time.

Choose New Process Fibre for Your Tooling Needs

New Process Fibre is focused on building long-term relationships by going above and beyond project standards to add extra quality steps. With our broad inventory of materials, advanced machinery, in-house tooling capabilities, and strict quality controls, we provide the highest quality nonmetallic stamped parts for all our customers.

To learn more about our tooling, machinery, or other capabilities, contact us today.

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