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.
The Various Types of Non-Metallic Washers
Washers comes in different shapes and sizes depending on their specific application, but are generally hardware components that are used to distribute force, prevent leaks, space out other components, and alleviate friction. A few examples of our most popular washers are plain/flat washers, self-retaining washers and our specialty shapes category.
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.
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.
New Process has a large array of options to meet your Specialty Washer designs. We possess an in-house capability to create any non-metallic washer needed for the job. With provided specs for inner dimension, outer dimension and thickness, we can create just about anything you need.
A couple of our most popular specialty designs tend to be “C” shaped and “D” Shaped washers
- C Washers are especially important due to their ability to be placed in hard to reach spots without taking pieces apart. The washer’s actual “C” shape opening allows for it to be latched on easily.
- D Washers are specially cut in order to be used in substitute of flat washers due to space limitations. The D washer’s special cut and dimensions allow for this unique fit.
- In addition to our special shapes, another key benefit of these washers is that they are PSA (Pressure Sensitive Adhesive) and can be placed into the spots they need to be while the job is being worked on. This allows for a worker to freely use both hands on the job.
Types of Non-Metallic Materials
Non-metallic washers are made from synthetic materials, polymers, and plastics in a variety of different colors. Frequently used materials include:
- Acetal Copolymer. Acetal copolymer is a stiff synthetic material that has excellent strength, durability, and dimensional stability, which helps prevent Acetal copolymer washers from deforming during manufacture and use.
- Stiff, strong, and highly resistant to impact damage, Delrin homopolymer is a common alternative to the traditional plastics used to create non-metallic washers.
- Washers composed of Nylon are lightweight, non-toxic, and feature high resistances to friction, fire, and corrosion.
Nylon 6 and Nylon 6/6: Nylon 6is the same material found in fabric, but we use it as a replacement for brass, steel, aluminum, and other metals. Its high strength makes it suitable for gears, spacers, washers, and plumbing parts. Nylon 6/6 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. To see how our non-metallic washers can be used in your operation, feel free to contact us today.