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.
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
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.
Plastic extrusion is a highly customizable fabrication process that uses thermoplastic resins and a pre-shaped die to create components at high volumes. This manufacturing method can utilize different extrusion techniques based on the needs of the end application.
Polyethylene plastics are some of the most commonly used plastics on the market today. They are found in products you use every day, from water bottles to sandwich bags to garbage cans. Polyethylene plastics can be further broken down into High-Density Plastics (HDPE) or Low-Density Plastics (LDPE).
Polyethylene plastic is created through the polymerization of petroleum. Although HDPE and LDPE are both polyethylene plastics, they have visible differences. This is due to the differences in the manufacturing process. LDPE has an amorphous structure that isn’t organized, while HDPE has either a partially or completely crystalline structure, making it stronger and more durable.
High-Density vs. Low-Density Polyethylene
High-density polyethylene is a petroleum product. This polymer is melted into liquid form for easy molding and shaping. This allows manufacturers to create custom-shaped, durable containers. During manufacturing, HDPE experiences very little polymer branching, keeping the molecular structure very tight. The resulting material is strong and more rigid with the ability to retain its shape under pressure.
HDPE is ideal for projects that require custom printing or coloring. Since it’s both easy to manufacture and incredibly strong, it’s a preferred material for packaging. HDPE can also be made food-safe and it is capable of withstanding caustic chemicals.
LDPE is a lighter and more flexible plastic. LDPE polymer chains experience a considerable amount of branching and spreading. Since the chains are separated or scattered, the plastic has far less structure. The resulting plastic is lighter and more flexible. Its softness, however, means it is prone to damage.
Similarities Between HDPE vs. LDPE
There are numerous similarities between the two polyethylene plastics. Both plastics have a low material weight, are highly recyclable and have a high impact strength, and can be resistant to water vapor, weathering, and even chemicals. The tensile strength of both plastics ranges from 0.02 to 0.40 N/mm2 and are cost-effective to manufacture. Polyethylene is naturally inert, which provides both HDPE and LDPE with excellent mechanical and electrical properties.
Differences between HDPE & LDPE
The different production methods of the two substrates give them very distinct properties. These include:
Physical Characteristics: HDPE is much sturdier than LDPE. LDPE has a lower melting point and the products are usually more transparent than HDPE products. LDPE is slightly abrasion-resistant but is the more fragile of the two plastics. HDPE is more rigid. This durability makes it more resistant to chemicals. It has a higher melting point, which means it can withstand greater temperatures. Unlike LDPE, it’s much less transparent. HDPE is fully abrasion-resistant.
Recyclability: Both plastics can be recycled, but have different recycling requirements. LDPE is a recycling number 4 product and is more difficult to recycle due to its softness, increasing the risk of binding or clogging recycling machinery. HDPE is a recycling number 2 product and is easier to process through the recycling equipment.
Production Methods: HDPE is manufactured by heating petroleum to an extreme temperature. This releases ethylene gas monomers, which combine to form the polymer chains. LDPE is created by compressing the monomer ethylene gas within a tubular reactor, or autoclave, to facilitate linking monomers, creating the polymer chain.
Applications of HDPE vs. LDPE
HDPE and LDPE are often used in the same industries, but for different purposes. These industries include:
Hydraulics and pneumatics
Automotive
Packaging
Pipe and Piping
Electrical
HDPE plastics are used in applications such as:
Food processing
Chemical and petroleum manufacturing
Pharmaceutical processing
LDPE plastics are used for applications such as:
Food processing
Paper processing
In the marine market
HDPE Solutions from New Process Fibre
While both HDPE and LDPE thermoplastic have their advantages, HDPE plastic creates more durable products for a wide range of applications. New Process Fibre specializes in complete HDPE stamping and die-cutting services. We are an ISO 9001:2015-certified manufacturer that provides custom thicknesses, widths, and colors to meet your project’s requirements.
Contact us for further information on our HDPE solutions.
Plastic extrusion involves a top-mounted hopper system that feeds thermoplastic resin through an extruder barrel. With the help of heat and pressure, the plastic takes the shape of the mold. Manufacturers can incorporate additives like colorants and UV inhibitors to enhance the appearance or performance of the final product.
Extrusion works with a variety of thermoplastic materials, including:
Teflon PTFE
Nylon (6, 6/6, MDS)
Polypropylene (PP)
Low-density polyethylene (LDPE)
High-density polyethylene (HDPE)
High-impact polystyrene (HIPS)
Flexible polyvinyl chloride (PVC)
Acrylonitrile butadiene styrene (ABS)
Thermoplastic elastomers (Santoprene®)
Polyethylene terephthalate glycol (PETG or Codar®)
There are five main types of plastic extrusion methods that use different types of extrusion dies. We will describe the benefits and applications of each type of extrusion to help you determine the ideal method for your application.
Sheet Extrusion
Sheet extrusion works by extruding a molten plastic material in powder, flake, granule, or pellet form through a die into a flat shape. Rollers cool the sheets, which can be between 0.2 and 15 mm. Thin sheets are ideal for consumer products, while thicker sheets are best for industrial or commercial applications. The following are examples of applications for these extruded flat sheets:
Washers
Spacers
Discs
Fasteners
Gaskets
Insulators
Shims
Tags
And more
Thermoplastic Extrusion Services from New Process Fibre
Thermoplastic extrusion is one of the most versatile manufacturing methods. It can produce hollow tubes, sheets of varying thickness, plastic parts with unique properties, plastic wire insulation, and uniform films for packaging.
At New Process Fibre, our specialization in non-metallic products allows us to deliver high-quality thermoplastic extrusion services. We collaborate with our clients from start to finish, ensuring our products meet their goals and expectations. Contact us today to place an order or to speak with a representative about our extrusion capabilities.
As a common alternative to metal washers, plastic washers for screws provide watertight seals, minimize vibrations, and offer unique benefits over their metal counterparts. These opaque or clear plastic washers are available in a wide range of material options to suit nearly every application. Here, we’ll discuss when to use plastic washers, including the common materials to consider when selecting a washer for your specific application.
Plastic Washers
Like metal washers, plastic washers are disks with a hole in the center and function primarily to distribute a fastener’s load. Because of their nonmetal composition, plastic washers do not cause sparks, creating a safer and more reliable work environment. Plastic washers also streamline production by decreasing maintenance downtime.
For these reasons, plastic washers are an attractive, cost-effective option for many applications. Other benefits of plastic washers include:
Vibration and shock resistance
High-temperature resistance
Weather resistance
Water and moisture resistance
Nonmagnetic
Nonflammable
Nontoxic
Plastic Washer Material
Plastic washers come in a variety of material options. The best one depends on the unique needs of your application. Here are the most common plastic washer materials:
Nylon: Nylon is a highly versatile synthetic material that comes in several types and offers flexibility, abrasion resistance, chemical resistance, and machinability. This material is preferable for electrical and chemical applications due to its excellent absorption and insulation properties. Nylon washers are also a durable, lightweight alternative to metal washers in weight-sensitive applications.
Teflon™: Also known as PTFE, Teflon™is known for its extremely low coefficient of friction and resistance to water and oil. Compared to other washer materials, Teflon™ offers exceptionally high chemical and thermal resistance properties. These low-friction washers are ideal for HVAC, automotive, and plumbing applications.
Delrin®: Delrin® is a patented homopolymer with a stable crystalline structure that offers dimensional stability, stiffness, and durability in heavy-duty applications. The material also provides impact and temperature resistance from -50 °C to 90 °C, making Delrin® washers ideal for applications ranging from consumer goods to military equipment.
Polyethylene (PE): We offer both low-density polyethylene (LDPE) and high-density polyethylene (HDPE) washers. The flexibility of LDPE washers is ideal for water-resistant applications in drains, water systems, and fluid feeds. HDPE washers are stronger and less flexible, so they are better suited to mechanical and industrial applications that value crush and abrasion resistance.
Plastic Washer Applications
Plastic is an exceptionally versatile and low-cost material for washers. The following applications rely on plastic washers:
Power tools
Furniture
Fasteners
Medical
Farm and Garden
Marine
Aerospace and Military
Government
Sporting Goods / Fitness Equipment
HVAC
Plumbing
Electronics
Consumer and Kitchen Appliances
Automotive
Plastic Washers From New Process Fibre
Plastic washers are a reliable alternative to metal washers for distributing fastener loads. Four of the most common materials include PE, Delrin®, Teflon™, and Nylon, each of which offers unique advantages.
To select the best plastic washers for your application, consult with an industry professional. Since 1927, New Process Fibre has been a leader in custom nonmetallic solutions.Contact us to learn more about our plastic washers for OEM equipment across diverse industries.
Plastic stamping is a manufacturing process that enables the creation of very thin parts. Typically, this process utilizes a set of dies and a punch press. The press is available in both conventional and high speed options, with varying tonnages depending on the equipment. This machinery is able to punch a shape from a non-metallic substance such as extruded plastic. Manufacturers can utilize plastic stamping to create an array of flat shapes, including gaskets and washers.
What Dies Are Used in Plastic Stamping?
Dies are highly versatile, with applications across a wide range of industries. The plastic stamping process will most commonly utilize a compound die, which consists of two separate dies. One cuts the outside diameter of the workpiece, while the other punches the interior. After the plastic stamping is complete, high pressurized air will blow away any excess material. The benefit of compound dies is that they enable all stamping to be completed in a single stroke, rather than two separate strokes.
New Process Fibre differs from many other stamping companies, as we specialize in stamping high performance non-metallic materials. We offer an array of stamping solutions, from single stroke compound dies to high-speed progressive dies. This enables us to meet the needs of every customer looking to manufacture high quality non-metallic products.
What Materials Are Considered for Plastic Stamping?
There are many advantages to choosing non-metallic materials over metal ones. Each non-metallic material boasts its own unique properties, enabling them to meet the needs of an array of applications. The materials commonly used for plastic stamping include:
Vulcanized fibre
Laminates
Thermoplastics
Vulcanized Fibre
This material is typically made from a combination of paper, rag, and wood pulp. It offers an excellent strength to weight ratio, and is resistant to impacts and abrasion. It also offers high flammability ratings. As such, vulcanized fibre is a popular choice in the automotive and electrical industries.
Laminates
Commonly found in industries such as petroleum, aerospace, and automotive, laminates are composed of resin. The National Electrical Manufacturers Association (NEMA) grades laminates for mechanical and chemical performance properties.
Thermoplastics
Thermoplastics are a highly versatile option, as they may be composed of a variety of different materials. These include:
Polypropylene copolymer and homopolymer
Polyethylene HDPE & LDPE
Teflon
Acetal copolymer & Delrin homopolymer
Nylon 6, 66 & MDS
G-10 FR4 Nema Grade
Thanks to their versatility, thermoplastics are a popular choice for many consumer products.
New Process Fibre’s Custom Plastic Stamping Capabilities
For stamped parts with unconventional shapes or dimensions, the ability to design custom tooling and dies is invaluable. At New Process Fibre, our in-house tool room offers CAD/CAM and wire EDM capabilities, enabling our design engineers to create custom tooling suited to the unique specifications of every project. We are also able to stamp a wide array of non-metallic specialty materials, including:
Acetal & Delrin
Teflon
Nylon 6,66 & MDS
Vulcanized fibre
High and low density polyethylene
G-10 FR4 Nema Grade
Our range of material options and custom tooling enables us to work on projects in industries ranging from consumer goods and plumbing to aerospace, military, and automotive.
Due to the fact that we maintain ownership of the tool throughout the lifetime of the stamped part, our customers do not need to worry about maintaining or storing the tool for future use. We also provide inventory and storage for any excess production volumes, thus enabling us to provide lower overall costs.
Custom Plastic Stamping Solutions From New Process Fibre
Since 1927, New Process Fibre has been dedicated to innovation and growth. Our operation began from a desire to design a more efficient and cost-effective process for creating vulcanized fibre from cotton paper. We have continued this trend of innovation for nearly a century, performing all our manufacturing in-house to provide our customers with the highest quality non-metallic stamped parts. Our expansive array of production equipment in combination with our customization capabilities enables us to meet the needs of any project, large or small. To learn more about our plastic stamping solutions, contact us today.
Many applications require the use of washers. Washers are responsible for distributing the pressure of a nut over a surface, reducing the risk of the nut loosening at any point. While metal is one of the most commonly used materials for washers, there are other materials available depending on the needs of the application. Non-metallic or plastic washers are made from a variety of materials and offer a wide range of benefits when compared to metal washers, making them highly sought after by many industries.
Types of Non-Metallic Washers
Plastic washers are frequently used across a wide range of applications because of plastic’s diverse properties. Some commonly used types of non-metallic washers include:
Nylon. Nylon washers are often used due to their high strength, low-friction, and wear-resistant properties. They’re capable of withstanding most types of corrosive substances, and they are frequently used in electrical and thermal insulators.
HDPE. This material is used in washers because of its reliability in many applications, from food processing equipment to oil tanks. HDPE is highly flexible, watertight, resistant to low temperatures, and withstands harsh weather conditions.
LDPE. Many applications rely on LDPE because of its low-temperature resistance, including equipment in the construction industry, sporting goods, and refrigerator components. This material is flexible and features low water absorption, high impact strength, and resistance to substances such as acids, bases, and alcohol.
PTFE. Chemical containers and laboratories often use PTFE washers. They may be used in parts such as gears, bearings, and other moving components.
Vulcanized Fibre. Vulcanized Fibre is a laminated plastic composed of natural cellulose. Vulcanzied Flat Fibre Washers made from this material is an excellent alternative in many applications. One of the first plastics ever developed. Vulcanized Fibre is a tough, resilient
What Are the Benefits of Using Non-Metallic Washers vs. Steel?
There are several key benefits of using non-metallic washers compared to metal. These advantages include:
Cost-Effectiveness
Non-metallic washers often cost less than metal washers. If you can achieve the same results with non-metallic washers as you would with metal washers, you will save more money by using them for your project.
Excellent Sealing Capabilities
Non-metallic washers have the ability to compress under pressure, making them ideal for sealing applications exposed to critical environmental conditions.
Lightweight Design
Due to their lightweight design, non-metallic washers can save you money on orders of products where excessive weight is a concern.
Insulating Properties
Non-metallic washers are also great for applications that involve the use of electricity or extreme temperatures due to their excellent insulating properties.
Resistance to Impact, Corrosion, Temperature, Wear, and Vibration
Based on the needs of your application, you can select non-metallic washers made from materials that can withstand certain conditions, such as exposure to corrosive elements. Materials such as polycarbonate absorb impact shock and isolate stress points. PTFE, nylon, Acetal, and UHMWPE offer lubricity to improve the longevity of parts, and other plastics have been developed to withstand extreme temperatures without severely compromising mechanical properties.
Safety
Non-metallic washers are safer to use in certain hazardous environments because they don’t generate sparks. Certain plastic washers are also made with fire-retardant grades.
What Industries Do We Find Non-Metallic Washers in?
When building new equipment, manufacturers often use non-metallic washers for various applications. For instance, medical manufacturers may use nylon washers in the production of medical instruments, while the plumbing industry often uses nylon washers for developing watertight, durable seals. The fire safety industry also relies on nylon washers in sprinkler systems.
Some of the many industries that use non-metallic washers include:
Sporting goods
Medical
Food
Electric
Manufacturing
Construction
Kitchen appliances
Plumbing
Power tools
Automotive
Non-Metallic Washers from New Process Fibre
The reliability, cost-effectiveness, and various other benefits of non-metallic washers make them an ideal solution for various applications and industries. At New Process Fibre, we offer flat and specialty non-metallic washers using materials such as nylon, PTFE, HDPE, LDPE, and many more. As a one-stop shop manufacturer, we are capable of executing custom non-metallic orders to meet our customers requirements and specifications. To learn more about our nylon washers, please visit this page. For more information, or to get started on your non-metallic washer solution, contact us or request a quote today.
At New Process Fibre, we specialize in designing and manufacturing non-metallic washers for a variety of industries and applications. Non-metallic washers feature a long service life, high durability, superior shock absorption capabilities, excellent noise cancellation, and lower production costs in comparison with their metallic counterparts. In this blog post, we will explain the various types of non-metallic washers, the materials used to make them, and their applications.
The Various Types of Non-Metallic Washers
Washers comes in different shapes and sizes depending on their specific application, but are generally hardware components that are used to distribute force, prevent leaks, space out other components, and alleviate friction. A few examples of our most popular washers are plain/flat washers, self-retaining washers and our specialty shapes category.
Plain Washers
While there are a variety of washers on the market, perhaps what most individuals are familiar with are our flat washers that primarily distribute force and protect the object to which the fastener is being anchored. They are available in an array of materials, also coming in custom inner dimensions, outer dimensions and thickness. In situations with pre-drilled holes, plain washers can be used to rectify improperly sized holes that are too big for the fastener.
The following plain washers are some of the more commonly seen and are each used for different applications:
Flat washers are multi-purpose washers that can adequately perform in most standard situations.
Shoulder washers are typically used to insulate screws and wires.
Fender washers see broad usage in automobiles, plumbing operations, and electrical systems.
Torque washers are used to prevent nuts from spinning.
C-washers are slotted washers that are designed to be easily maneuvered and readjusted.
Self-Retaining Washers
At New Process Fibre we have extensive experience with stamping a variety of washers to meet the needs of our customers in a variety of applications. When manufacturing our non-metallic washers, one particular specialty is our self-retaining washers, which we stamp flat with protrusions coming out of the inside diameter to easily grip the screw. Typically, we stamp these tabs with triangles or stars, but we can accommodate other designs as well and we can offer hex IDs as well as slit IDs that can offer a bit of give.
In the automotive industry, it’s common to work with upright screws. Retaining washers are preferred for this scenario because they remain affixed as they’re screwed in.
Retaining washers can perform a vast array of tasks ranging from the very simple, such as those of the basic screw and washer, to the more complex, like what wire guides and quarter-turn fastener assemblies do.
Specialty Shapes
New Process has a large array of options to meet your Specialty Washer designs. We possess an in-house capability to create any non-metallic washer needed for the job. With provided specs for inner dimension, outer dimension and thickness, we can create just about anything you need.
A couple of our most popular specialty designs tend to be “C” shaped and “D” Shaped washers
C Washers are especially important due to their ability to be placed in hard to reach spots without taking pieces apart. The washer’s actual “C” shape opening allows for it to be latched on easily.
D Washers are specially cut in order to be used in substitute of flat washers due to space limitations. The D washer’s special cut and dimensions allow for this unique fit.
In addition to our special shapes, another key benefit of these washers is that they are PSA (Pressure Sensitive Adhesive) and can be placed into the spots they need to be while the job is being worked on. This allows for a worker to freely use both hands on the job.
Types of Non-Metallic Materials
Non-metallic washers are made from synthetic materials, polymers, and plastics in a variety of different colors. Frequently used materials include:
Acetal Copolymer. Acetal copolymer is a stiff synthetic material that has excellent strength, durability, and dimensional stability, which helps prevent Acetal copolymer washers from deforming during manufacture and use.
Stiff, strong, and highly resistant to impact damage, Delrin homopolymer is a common alternative to the traditional plastics used to create non-metallic washers.
Washers composed of Nylon are lightweight, non-toxic, and feature high resistances to friction, fire, and corrosion. Nylon 6 and Nylon 6/6: Nylon 6is the same material found in fabric, but we use it as a replacement for brass, steel, aluminum, and other metals. Its high strength makes it suitable for gears, spacers, washers, and plumbing parts. Nylon 6/6is a high viscosity Nylon with exceptional strength and temperature resistance. It is often used in chemical and electrical applications.
Suitable for wet or submerged applications, Mylar washers resist shrinkage, do not absorb a lot of moisture, and won’t change shape from moisture absorption.
Teflon â Teflon ÒPFTE is a pseudo-invulnerable synthetic material that easily withstands physical force and chemical damage.
High/Low Density Polyethylene. Low density polyethylene washers are valued for their flexibility, which makes them useful in applications that require a tight seal on geometrically unusual joints. High-density polyethylene washers are stronger than LDPE, but less flexible.
Vulcanized Fibre. Comprised of wood pulp, paper, and rag material, vulcanized fibre outperforms many standard materials with its light, stiff, and tough qualities.
Lexan has high impact resistance and a high strength-to-weight ratio. It is 200 times more impact resistant than glass while being 5–6 times lighter.
Ultra-High Molecular Weight Polyethylene. Perfect for applications that require a leak-free seal, ultra-high molecular weight polyethylene washers have a low-friction surface while also resisting abrasion, chemical damage, impact damage, and moisture
Why Use Non-Metallic Washers from New Process Fibre?
At New Process Fibre, we’ve spent the last century perfecting and innovating our design and manufacturing non-metallic washers. Our non-metallic washers are a cost-effective, reliable alternative to metallic washers for nearly any application. For more information about our nylon washers, please visit this page. To see how our non-metallic washers can be used in your operation, feel free to contact us today.
Plastic stamping offers an ideal plastic forming method for the affordable production of simple plastic goods in virtually any volume. When compared to machining, plastic stamping offers lower material costs, better repeatability, and faster production speeds when creating custom plastic components.
An essential process for many industries that create plastic and polymer parts, successful plastic stamping requires experienced personnel and state-of-the-art equipment to ensure success. This blog will explore the plastic stamping process, it’s benefits, and some of the available options it provides.
What are the Major Benefits of Plastic Stamping?
Plastic components are prized for their low weight, varying levels of hardness, and resistances to chemicals, heat, friction, and deterioration. Beyond this versatile range of physical properties, plastic stamping process offers a variety of other benefits, such as:
Accuracy
Plastic stamping machinery creates precisely manufactured components. Using durable dies to cut plastic parts from stock material, plastic stamping equipment offers excellent repeatability between parts within very tight tolerances. As long as the plastic stamping die stays in good condition, accurate and dimensionally consistent parts can be produced in virtually any volume.
Aesthetic Component Appearance
Plastic stamped components are blanked in a single operation, drastically lowering the likelihood of error. Components created via plastic stamping have crisp, uniform edges and an overall high level of uniformity that contribute to their aesthetic appeal. This single-operation process often minimizes or mitigates the need for secondary finishing processes.
Speed and Cost Efficiency
The speed at which identical components can be produced is often considered the ultimate benefit of plastic stamping. Some manufacturing facilities contain high-speed punches that are capable of cycling at speeds as fast as 400 strokes per minute while still producing highly precise components. Large-volume orders are extremely cost-effective, and the speed at which plastic stamping machines operate provides additional economies of scale on larger orders.
What are the Key Material Options fo Plastic Stamping?
Plastic stamping materials have variable characteristics in terms of appearance, elasticity, plasticity, strength, hardness, brittleness, and more. While a standard material is available to suit most applications, plastic materials can be formulated with specific physical characteristics in mind. Plastic materials also typically come in a variety of colors and can be easily color-matched when necessary. This makes it relatively straightforward to tailor the material to the part’s intended application.
Common plastic stamping materials include:
Film
Foam
Laminate
Phenolic compounds
Plastic compounds
Rubber compounds
Vulcanized fiber (fish paper)
When deciding upon a material to use, the material’s brittleness plays a key role in the selection process. Hardness and brittleness tend to cohere, making it vital to select a material for the intended component that is hard enough to withstand the rigors of the intended use case without sacrificing formability.
Is Plastic Stamping Ideal and Affordable?
The plastic stamping process relies on a punch press and an associated set of stamping dies that punch an extruded plastic stock sheet or coil stock into the form specified by the design. As the stock material moves through the machine, pressure is applied to a single die or multiple dies in succession to cut the part from away from the stock. This method is ideal for the high-volume production of simple, flat items such as gaskets, seals, washers, laminations, and more.
Why Choose New Process Fibre for Plastic Stamping?
At New Process Fibre, our aim has always been to maintain the highest of quality standards in both our products and our business practices. Since our inception in 1927, we have continuously raised these qualities standards, allowing us to increasingly push the boundaries of what is possible regarding plastic stamping.
We are always seeking ways to improve our processes, technologies, and equipment, but one facet of our quality standards that we prize above all others is the people we hire to work behind the machinery. From figuring out more efficient ways to run a punching press to developing rapport with a new customer, our skilled employees are the best investment we could ever make, granting us the opportunity to lower costs, improve timeframes, and advance product quality for our valued customers.
Plastic stamping can be an affordable and ideal method when utilized to produce a variety of identical, quality components while saving customers time. For more information on how seriously we take quality standards, check out how we implement our quality assurance program. For any other questions, feel free to contact us today.
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.
High-density polyethylene is a petroleum product. This polymer is melted into liquid form for easy molding and shaping. This allows manufacturers to create custom-shaped, durable containers. During manufacturing, HDPE experiences very little polymer branching, keeping the molecular structure very tight. The resulting material is strong and more rigid with the ability to retain its shape under pressure.
HDPE and LDPE are often used in the same industries, but for different purposes. These industries include:
Teflon PTFE
Like metal washers, plastic washers are disks with a hole in the center and function primarily to distribute a fastener’s load. Because of their nonmetal composition, plastic washers do not cause sparks, creating a safer and more reliable work environment. Plastic washers also streamline production by decreasing maintenance downtime.
Plastic is an exceptionally versatile and low-cost material for washers. The following applications rely on plastic washers:
The Various Types of Non-Metallic Washers
