Plastic Extrusion Guide

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

HDPE WashersHigh-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

LDPE washersHDPE 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.

Types of Thermoplastic Extrusion

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:

  • extrusionTeflon 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.

When to Use Plastic Washers

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

delrin washersLike 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

acetal washersPlastic 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.

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.


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 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:


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.


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 6 is 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:


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

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 Spacers 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.


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