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A Guide to Plastic Stamping

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?

CNC punching machine

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

nylon-6

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.

Guide-to-Plastic-Stamping infographic

Plastic Washers vs Metal Washers

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.

plastic washers

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.

Manufacturing Non-Metallic Washers and Their Variety of Applications

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.

new process washersThe 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.

specialty shape washers

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 6/6 is 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.

Why Choose Plastic Stamping?

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. vulcanized fibre parts

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 materials

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.

Why Use Nylon Over Metal?

Nylon is a highly versatile material used in the manufacture of a wide range of industrial parts and products, including gears, spacers, washers and provides various benefits and applications. It is available in several variations (e.g., Nylon 6 and its derivatives, Nylon 6/6 and Nylon MDS), each of which demonstrates unique characteristics that make it suitable for different use cases. Similar to all washers, nylon washers facilitate even pressure distribution, protect against surface damage, and prevent fastener loosening over time. However, compared to metal washers, they offer a number of advantages, such as greater durability and longevity, better shock and noise absorption properties, and lower production costs.

The following blog post discusses why it is better to use nylon over metal for industrial components such as washers. It provides an overview of the types of nylon available, the benefits of using nylon over metal, and typical applications of nylon materials and nylon washers.

Types of Nylon

Nylon is a synthetic thermoplastic characterized by its exceptional strength, elasticity, temperature resistance, and chemical compatibility. These qualities, combined with its low-friction properties, make it ideal for use in the construction of washers. While each nylon variation exhibits these characteristics, the degree to which they do varies depending on the exact formulation. quality nylon icon

  • Nylon 6 is the non-toxic base formulation on which other variations (e.g., Nylon 6/6 and Nylon MDS) are based. It demonstrates high tensile and impact strength, elasticity, abrasion resistance, and machinability. Additionally, it can be combined with carbon or glass fibers to enhances its performance characteristics. As a washer, it is often used in food processing equipment.
  • Nylon 6/6 is a variation of Nylon 6 that offers better tensile strength, material stiffness, dimensional stability, and temperature resistance. Similar to Nylon 6, adding fillers and fibers to the formulation can improve its functional qualities. As a washer, it is generally used in household appliances.
  • Nylon MDS is a variation of Nylon 6/6 containing small particles of molybdenum disulfide (MDS). The presence of these particles enhances the material’s loading bearing properties without sacrificing impact resistance. As a washer, it is typically employed in machinery.

Benefits of Nylon Over Metallic Counterparts

As indicated above, nylon washers have many advantages over metal washers. For example:nylon washers

  • Nylon washers are lighter and cheaper to manufacture than metal washers, resulting in cost savings for the manufacturer and, consequently, the end consumer.
  • Nylon washers are less susceptible to corrosion and surface wear than metal washers, meaning they will last longer than their metal counterparts.
  • Nylon washers are better at absorbing noise and shock than metal washers, which leads to smoother and quieter machine operations.

Applications of Nylon and Nylon Washers

Due to its numerous advantageous qualities, nylon is used to produce non-metallic components—such as bearings, bushings, gears, spacers, and washers—for a wide range of industries, including aerospace, construction, defense, manufacturing, medical and life sciences, and power generation and distribution. For example:

  • Its ability to withstand high voltages makes it suitable for washers used in electrical and electronic devices, equipment, and systems.
  • Its non-sparking and anti-magnetic qualities make it ideal for washers integrated into consumer and electronic appliances.
  • Its ability to increase its energy absorption capabilities and impact strength by absorbing more moisture makes it beneficial for washers installed in faucets, shower heads, and other plumbing elements.

High-Quality Nylon Washers From New Process Fibre

Nylon washers are quickly becoming an acceptable alternative to metal washers. In addition to their lighter weight, greater durability, and better insulating properties, they serve as a much more cost-effective option for washer applications.

For all your nylon washer needs, turn to the experts at New Process Fibre. Equipped with extensive non-metallic fabrication experience and state-of-the-art fabrication equipment, we can produce nylon washers to suit any customer application. To learn more about our nylon washers, please visit this page. For more information about our nylon washer offerings, contact us today.

Acetal Plastic vs. Nylon Plastic

Nylon and acetal are commonly used in a wide range of manufacturing applications. As both materials are a semi-crystalline thermoplastic, some of their characteristics overlap, such as their fatigue resistance, chemical resistance, and wear resistance with a sharp melting point. Additionally, both are appropriate material choices for the creation of small components such as washers, discs, and spacers. However, while there are some similarities in properties and use cases, the two materials remain distinctly different and are not entirely interchangeable.

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One of the most obvious differences between nylon and acetal lies is aesthetics; acetal is shiny, while nylon appears dull in comparison. They also vary in regard to performance. For example:

  • Compared to acetal, nylon offers superior tensile strength and bending stiffness. It can also handle higher loads and higher temperatures. However, it is susceptible to damage from UV radiation unless special additives are incorporated into its formula and reacts poorly to changes in humidity, which cause it to swell and lose tensile strength.
  • Compared to nylon, acetal provides higher impact resistance and cold resistance. It is suitable for moderate loads.

In the following article, we provide an overview of acetal and nylon—outlining what they are, their properties, their key benefits, and typical industry applications—to facilitate material selection.

What Is Acetal Plastic?

Acetal—also known as polyoxymethylene (POM)—is a synthetic polymer commonly used in precision engineering. Similar to other semi-crystalline thermoplastics, it has good chemical resistance and fatigue resistance. It also demonstrates excellent tensile strength, good dimensional stability and machinability, and low material weight and frictional properties. It is often used for the manufacture of stiff, dimensionally stable components that need low surface friction.

What Is Nylon Plastic?

Nylon is also a synthetic polymer, as well as one of the most commonly employed engineering thermoplastics in the industry. It is highly durable, demonstrating resistance to damage from abrasion, chemicals (such as alcohols, oils, and solvents), and tearing. These qualities, combined with the material’s low cost, make nylon a suitable option for all manner of industrial and commercial applications.

Properties of Acetal Plastic

As indicated above, acetal plastic is valued for its machinability and many advantageous physical characteristics. Some of the key attributes of acetal include:

  • Chemical resistance: excellent
  • Coefficient of friction: low
  • Dimensional stability: excellent
  • Electrical properties: good
  • Machinability: excellent
  • Porosity and moisture absorption: low
  • Tensile strength and stiffness: excellent
  • Wear resistance: excellent
  • Availability in FDA and USDA-compliant grades: yes

Properties of Nylon Plastics

The properties of nylon somewhat overlap with acetal, including regard to the following:

  • Chemical resistance: excellent
  • Coefficient of friction: low
  • Wear resistance: excellent
  • Availability in FDA and USDA-compliant grades: yes

However, the material also offers better thermal resistance, durability, and performance for the given price point.

Benefits of Acetal Plastic

Both nylon and acetal are suitable for use in applications that call for general-purpose engineering plastics. However, there are a few reasons why you may choose acetal over nylon. For example:

  • When manufacturing parts that require high dimensional stability
  • When the finished part or product will be regularly exposed to humidity or moisture
  • When the chemical and wear resistance of the material is critical

Benefits of Nylon Plastic

As a self-lubricating material, nylon is increasingly popular as a replacement for metal components that require external lubrication. Compared to parts made from metal, parts made from nylon are also much lighter, produce less noise during operations, and have longer service lives.

Nylon also offers advantages over other thermoplastics. For example:

  • Compared to acetal, it has higher temperature resistance, tensile strength, and stiffness, as well as lower material cost.
  • Compared to all other semi-crystalline thermoplastics, it offers the highest dielectric strength (in 6 cast formulas).

Industry Applications for Acetal and Nylon

As both acetal and nylon are highly versatile, it would be difficult to list all possible industry applications for either material. Additionally, since both materials are semi-crystalline thermoplastics, their similar material properties make them suited for similar use cases.

Common Acetal Plastic Applications

Acetal is used for the manufacture of a wide range of parts and products, including the following:

  • Bearings
  • Buckles
  • Bushings
  • Electrical parts and padding
  • Fasteners
  • Fixtures
  • Gears
  • Jigs
  • Manifolds
  • Rollers
  • Valves
  • Washers
  • Wear strips and padding

These components might end up in medical devices, conveyor systems, or other similarly complex assemblies.

Common Nylon Plastic Applications

Nylon remains best known by the public for its uses as a sturdy and durable fabric. However, beyond its use in clothing and other commercial goods, it also finds application in many industrial parts and products. Similar to acetal, it is regularly used for the production of the following components:

  • Bearings
  • Gaskets
  • Gears
  • Rollers
  • Seals
  • Washers
  • Wear Pads

As with acetal, these components are highly versatile and may be used in any number of industries. For example, nylon parts are often found in medical instruments, plumbing systems, and sprinkler systems. They also serve as alternatives to metal, wood, and rubber components in many engineering applications.

Nylon & Acetal Washers

Although washers are often thought of as made exclusively made from metal or rubber, thermoplastic washers have grown in popularity over the years. The main function of washers is to distribute the pressure experienced by a fastener across a larger surface area while also protecting the fastener and attachment surface. They can also help disperse vibrations produced during operations to minimize the risk of the fasteners loosening over time.

New Process Fibre offers a selection of both nylon washers and acetal washers. Nylon washers are available in Nylon 6, Nylon 6/6, Nylon MDS, or Nylatron®, depending on the needs of the application. They are cost-effective, consistent, and customizable within LP-410 quality standards. Acetal washers are custom-made and come in a range of natural or pigmented resins.

Nylon and Acetal Products From New Process Fibre

Nylon and acetal are highly versatile materials used in the fabrication of a wide range of industrial parts and products. For all your non-metallic fabrication needs, turn to the experts at New Process Fibre.

At New Process Fibre, we are an experienced fabricator specializing in processing non-metallic materials. We accommodate a broad selection of materials, including acetal, nylon, high-density polyethylene (HDPE), low-density polyethylene (LDPE), polypropylene homo and copolymer, and fire-retardant thermoplastics. Equipped with over nine decades of industry experience and a 55,000 square foot fabrication facility, we have the knowledge and tools to serve the fabrication needs of customers from industries ranging from aerospace and automotive to construction and consumer goods to power tools and plumbing.

Our full range of fabrication and finishing services includes:

  • In-house tool and die making
  • Sheet extrusion and slitting
  • Slitting and shearing
  • Non-metallic stamping
  • Custom embossing and screen printing
  • Pressure-sensitive adhesive (PSA) application

Using these services, we fabricate countless non-metallic components, including washers, spacers, gaskets, shims, and more. Whether you’re seeking assistance with nylon, acetal, or some other thermoplastic, we are well equipped to satisfy your fabrication needs.

For more information about our nylon washers, please visit this page. To find out more about our fabrication capabilities or partner with us on your next project, contact our team today.

Benefits of Teflon Washers in the Plumbing Industry

Excellent thermal insulation and chemical resistance properties make polytetrafluoroethylene (PTFE) suitable for many commercial and industrial applications. PTFE—more commonly known by DuPont’s brand name, Teflon™—is widely used to create solutions for the plumbing sector, such as washers and plumber’s tape.

Benefits of Teflon

PTFE is a good raw material for fabricating industrial parts due to its many beneficial properties. Some of these include:

  • Better heat resistance than Nylon, making Teflon washers ideal for use in heat-generating electrical equipment.
  • Exceptional thermal and electrical insulative properties—PTFE can withstand up to 500 volts per mil and up to 600° F.
  • High resistances to most common chemicals.
  • Poor water absorption, making Teflon suitable for use in wet environments.
  • The lowest coefficient of friction among all plastics, so it doesn’t typically require any sort of lubrication.
  • Excellent dimensional stability and creep resistance, despite high compressibility.

With these properties, Teflon parts provide consistent performance over a long service life. This makes PTFE a more cost-effective raw material than other plastics in many applications, including plumbing.

Common Plumbing Applications for Teflon

Teflon’s chemical inertness and hydrophobic properties make it a widely used material in the plumbing industry. Common plumbing applications include:

  • Washers used in plumbing are almost exclusively made from PTFE. Teflon also repels oil, so these washers are useful in piping or process systems that move oil or oil-containing fluids.
  • PTFE plumber’s tape prevents leaks by sealing the threads of joining pipes.
  • The dimensional stability of Teflon at high temperatures makes it an ideal choice for parts used in hot water applications.

New Process Fibre (NPF) is an ISO 9001:2015-certified company that fabricates standard and custom-designed washers with Teflon and other plastics. Our PTFE products are widely used in a broad range of industries, including plumbing. Our Teflon washers are available in diameters from 0.093–16 inches and thicknesses from 0.0002–0.125 inches.

We can also provide washers in many different colors. NPF manufactures custom ordered washers in English or metric units. We supply these custom washers with pre-applied pressure-sensitive adhesives as well.

For more information about our PTFE washers or other Teflon products, please contact us.

High Density Polyethylene

Choosing the right plastic is essential to the success of every manufacturing and packaging project. Most plastics are formed from any of six different popular plastics or a plastic mixture with concentrations of different resins.

Short-term storage containers, such as bottles and jugs, are usually made from high-density polyethylene (HDPE). This is a versatile and robust plastic. HDPE plastic containers are identifiable by the numeral “2” printed inside the container’s recycling symbol.

An Overview of HDPE

High-density polyethylene is produced from petroleum. It is a thermoplastic polymer—a polymer that melts into a liquid for easy forming and shaping. Manufacturers can easily create strong, customized containers by melting and treating HDPE.

The material is also ideal for custom printing and coloring, making it one of the most common materials for packaging. HDPE can also be made food-safe and it withstands caustic chemicals.

Given this versatility, it is used to make a variety of common containers such as:

  • Bleach bottles
  • Cutting boards
  • Milk jugs
  • Piping
  • Plastic bottles
  • Shampoo bottle

One of HDPE’s most essential characteristics is its strength. The plastic has a high degree of tensile strength, so it is resistant to breakage from tension and impact damage. HDPE also has a high melting point, so it won’t degrade from heat under general, non-factory conditions. These features make the material ideal for producing reliable containers for consumer products and materials being transported.

Other benefits of using HDPE include:

  • Easily recyclable
  • Resistant to corrosion, even when holding liquid
  • Can be melted and reshaped
  • High strength-to-density ratio, making it cost-effective for transporting materials and products

Differences Between HDPE and LDPE

High-density polyethylene is just one type of polyethylene. Low-density polyethylene is lighter and more flexible.

During fabrication, HDPE’s polymer chains endure minimal branching. This keeps the polymer’s linear molecules closely knit together. The chains crystallize in a tight formation, which gives HDPE its rigid and relatively dense structure. It can hold a firm shape, even under pressure.

Conversely, the polymer chains of LDPE undergo significant branching and spreading. The polymer chains are more diffuse and scattered, giving them much less structure. This makes the material lighter, more flexible, and more susceptible to damage.

As such, HDPE is preferred for most manufacturing and packaging purposes. It can form reliable, structured products such as toys, garbage cans, storage containers, jugs, and pipes. Recently, HDPE has also begun to replace cardboard as the preferred material for fireworks tubes. The plastic material is less likely to shatter during malfunctions and can be recycled once the firework has been used.

Low-density polyethylene is used to produce cling wrap, plastic bags, and other unstructured products.

Custom HDPE Solutions from New Process Fibre Today

HDPE is a sturdy, versatile material that provides an ideal material for manufacturing storage containers of many different types.

New Process Fibre specializes in complete stamping and die cutting services for HDPE. We also produce sheets, rolls, and coils of high-quality plastics in standard and custom colors at high speeds. We can provide HDPE in custom thicknesses, widths, and colors to meet your project specifications. We are an ISO 9001:2015-certified manufacturer.

Contact us today to learn more about our variety of plastic fabrication and stamping services or request a quote for your next project.

The Uses of Retaining Washers

Retaining washers guide cords, cables, wires, and chains in an assembled product. One hole allows the washer to be secured to other components using a screw or bolt. Another opening allows the line to be firmly attached to the washer, thus securing the line in the desired position. These simple devices have a number of important applications. Different materials and finishes allow manufacturers to create these products to fit their design needs and aesthetic expectations.

Applications for Retaining Washers

The properties of retaining washers make them ideal for industrial applications.

  • Flexible rings are easy to remove for maintenance and other production purposes. As part of the design, flexible washers allow enough movement to protect delicate mechanical parts.
  • Sturdy washers keep bolts, screws, and other components in place while keeping their shape.
  • Easy-to-install washers often ease the installation of other parts as well.

Retaining washers are an important part of many industries. In the automotive industry, manufacturers use these components to keep upright washers properly affixed. These components perform a number of vital tasks in industrial settings, from simple functions like securing screws to more advanced purposes like quarter-turn and wire guide assemblies.

Washer Types and Material Finishes

There are two main classifications for retaining washers:

  • Internal washers place protrusions in the center of the piece
  • External washers feature protrusions on the outer edges of the unit

The inside diameter of retaining washers are shaped to allow it to easily slide into place without compromising its ability to hold components in place. During the manufacturing process, the insides of washers are customized specifically for their intended use.

Metals used in the manufacture and finishing of retaining washers can be chosen to meet the requirements of the end product. Some of the more common manufacturing materials are:

  • Steel
  • Aluminum
  • Brass

Popular finishes include:

  • Nickel
  • Zinc
  • Tin
  • Silver
  • Cadmium

Customized Retaining Washers for Use in Manufacturing

Retaining washers are a versatile component in a diverse range of industrial applications. These components can be customized with internal or external support from a number of popular production metals. The look and function of washers are further specialized with the addition of finishes.

New Process Fibre Company produces high-quality retaining washers that fit our clients’ exact specifications. Learn more about your customization options by downloading the Non-Metallic Material Selection and Properties Guide. This report will familiarize you with the possibilities of production. When you’re ready, contact our representatives for a free consultation on your project.

An Overview of Lexan and Its Applications

What is robust enough for astronauts’ helmets, tough enough to stop bullets, but light enough for eyeglasses, and flexible enough to make DVDs?

The answer is Lexan, the world’s most versatile and widely used plastic. The properties listed below make Lexan suitable for a variety of applications ranging from water bottles to laptops to boats:

  • 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. For these reasons, Lexan is easier to transport, handle, and install than glass.
  • Lexan has low flammability, high polish, and glass-like clarity. However, for applications like eyeglasses, it requires a scratch-resistant coating since its surface can be easily scratched.
  • It’s flexible and can be molded without cracking. Lexan can be repeatedly heated and cooled without any deterioration in its properties.
  • It holds up well to high temperatures and corrosive chemicals.

Where Is Lexan Used?

Common Lexan applications touch every part of our lives. Industries that often use Lexan include:

  • Aerospace and automotive: These industries use Lexan to make strong but light windshields for planes, trains, and automobiles. This material is also used to build bullet-resistant windows for automobiles and isolation walls for bank counters.
  • Defense: Military manufacturers value Lexan for its light weight and high strength. This material is used to build components for military vehicles and jet fighters. Several accessories carried by soldiers are also made with Lexan to reduce the total weight that they carry.
  • Technology: The technology industry, especially electronic component manufacturing, uses Lexan because it insulates well against electricity and resists heat and corrosive chemicals. Lexan is used in large quantities to make CDs, DVDs, and Blu-Ray discs as well as computer and television screens. Lexan’s low weight and high impact resistance also make it suitable for use as laptop and cell phone cases along with video game controllers.
  • Environmentally friendly products: Eco-conscious products are composed of Lexan because this material is highly recyclable. Reusable water bottles, food containers, canteens, and glasses are made with Lexan. Lexan is far better than glass for these applications since it resists fractures while retaining the transparency of glass.

Why Is Lexan So Widely Used?

Lexan is so widely used because its properties make it an attractive raw material for industrial manufacturing. It has the good characteristics of similar materials like glass and acrylic without any of their weaker properties. Furthermore, Lexan’s undesirable qualities like poor scratch resistance and susceptibility to yellowing by UV rays can be easily addressed with protective coatings.

The main reason for Lexan’s large-scale use in manufacturing is its high impact resistance. It’s 200 times more impact resistant than glass, whereas acrylic’s impact resistance is only 8 times that of glass.

Additionally, Lexan can be fabricated in layers to make it bullet resistant. It’s also used to make containment-grade sheets to protect against forced entry with sledgehammers and similar tools. Bullet-resistant and containment-grade Lexan is much more cost effective than glass during fabrication and shipping.

Components made with Lexan are suitable for use in harsh environments because of Lexan’s resistance to high temperatures and harmful chemicals like acids. Despite its toughness and strength, Lexan is light and flexible, which makes it suitable for making eyeglasses, computer screens, and TV monitors.

Quality Lexan from New Process Fibre

New Process Fibre Company (NPF) has over 90 years of experience in providing industrial parts for a diverse range of manufacturers, and we offer many fabrication services as well. Our product catalog and service portfolio cover many thermoplastic materials, including Lexan.

Contact NPF today for all your Lexan requirements.

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