Madeinusa

CNC PROTOTYPES

CNC machined prototypes

About CNC Prototypes

CNC machining is a subtractive process utilizing 3D CAD files of your part to generate a prototype from virtually any material - either from our inventory or special order. Our abilities allow us to create CNC machined parts quickly and with the highest quality standards. We offer a variety of expertly applied finishing options including painting, anodizing, EMI and RFI shielding, and hand polishing.

Applications include:
- Prototypes from production materials
- Assembly and quality inspection fixtures
- Functional durable prototypes
- Display models
- Low volume production parts
- Mechanical assemblies

CNC Process

CNC machining combines the responsiveness of additive manufacturing processes with parts that are milled from real engineering-grade plastic and metal for improved material selection, part functionality and cosmetic appearance. Final parts are nearly indistinguishable from molded parts, making for high-quality prototypes often used as jigs, fixtures and one-offs.

During the machining process, a solid block of material is clamped into a CNC mill and cut into a finished part. We employ four-axis milling from up to six orthongonal sides of the part to machine as many features as possible. The range of material choices allows parts to be made with the desired material properties, and good tolerances yield parts suitable for form, fit, and function testing.

CNC Prototypes Specification Guidelines

Outlined below are the options which need to be specified when ordering a CNC prototype.

Standard Materials: PLASTIC

ABS is known for its strength, impact resistance, and cost-effectiveness. It is widely used in various applications such as automotive, electronics, and toys.

  • Color: Beige or Black
  • Max. Temperature: 140° F
  • Tensile Strength: 4,200-5,100 psi (Poor)
  • Impact Strength: 6.3-7.7 ft.–lbs./in. (Excellent)
  • Hardness: Rockwell R101-R109 (Hard)
  • For Use Outdoors: No
  • Specifications Met: UL 94 HB

High strength and water resistance, along with a variety of color choices, makes it useful for outdoor sign and containers. This material is also known as Lucite and Plexiglass® acrylic.

  • Color: Clear
  • Temperature Range: -40° to 170° F
  • Tensile Strength: 10,000-11,250 psi (Good)
  • Impact Strength: 0.3-0.4 ft.–lbs./in. (Poor)
  • Hardness: Rockwell M94-M100 (Hard)
  • For Use Outdoors: Yes

 

  • Color: Black & White
  • Temperature Range: -40° to 170° F
  • Tensile Strength: 10,500 psi (Good)
  • Impact Strength: 0.04-0.5 ft.–lbs./in. (Poor)
  • Hardness: Rockwell M100 (Hard)
  • For Use Outdoors: Yes

Used when resistance to high temperature is required. It also resists acids and alkalies, and is widely used to make parts for use in chemical processing applications. Also CPVC is an excellent electrical insulator.

  • Color: Gray
  • Temperature Range: 32° to 200° F
  • Tensile Strength: 7,090-7,750 psi (Good)
  • Impact Strength: 1-2 ft.–lbs./in. (Poor)
  • Hardness: Rockwell R118-R119 (Hard)
  • For Use Outdoors: No
  • Specifications Met: UL 94 V-0

Used when slippery, wear-resistant surface is desired.

  • Color: White or Black
  • Temperature Range: -20° to 180° F
  • Tensile Strength: 10,000-11,000 psi (Good)
  • Impact Strength: 1-1.5 ft.–lbs./in. (Poor)
  • Hardness: Rockwell R120-R122 (Hard)
  • For Use Outdoors: No
  • Specifications Met:
    White: ASTM D6100, FDA Compliant 21 CFR 177.2480
    Black: ASTM D610

This is a unique thermoplastic used in moving parts which require low friction and long wear life. It is a combination of PTFE fibers uniformly dispersed in Delrin® acetal resin. Often used for bearings, bushings, electrical components, gears and rollers.

  • Color: Brown
  • Temperature Range: -40° to 185° F
  • Tensile Strength: 7,690-8,100 psi (Good)
  • Impact Strength: 0.7-1 ft.–lbs./in. (Poor)
  • Hardness: Rockwell R115-R118 (Hard)
  • For Use Outdoors: No
  • Specifications Met: ASTM D6778, UL 94 HB

Nylon 6/6 is used when high mechanical strength, abrasion resistance, rigidity, heat & chemical resistance are required. Used in bearings, gears, and valve seats.

  • Color: Off-White or Black
  • Temperature Range: -40° to 185° F
  • Tensile Strength: 11,200-12,300 psi (Good)
  • Impact Strength: 0.6-1.4 ft.–lbs./in. (Poor)
  • Hardness: Rockwell R108-R121 (Hard)
  • For Use Outdoors: No
  • Specifications Met:
    Off-White:
    7/64“ Thick. and smaller: ASTM D5989, ASTM D6779, FDA Compliant 21 CFR 177.1500, UL 94 HB
    1/8“ Thick. and larger: ASTM D5989, ASTM D6779, FDA Compliant 21 CFR 177.1500, UL 94 V-2
    Black: ASTM D5989, ASTM D6779

PEEK has a unique combination of high-temperature strength along with, wear & chemical resistance. Often chosen as a lightweight substitute for metal parts in chemical-processing applications. It is used in aerospace, electronics components and medical implants.

  • Color: Beige
  • Temperature Range: -20° to 480° F
  • Tensile Strength: 14,000-16,000 psi (Excellent)
  • Impact Strength: 0.6-0.95 ft.–lbs./in. (Poor)
  • Hardness: Rockwell R126 (Hard)
  • For Use Outdoors: No
  • Specifications Met:
    1/16″ to 1/8″ Thickness: 3-A Certified 20-27, FDA Compliant 21 CFR 177.2415
    1/4″ to 1 1/2″ Thickness: FDA Compliant 21 CFR 177.2415, MIL-P-46183, UL 94 V-0

Polycarbonate has exceptional impact strength, heat and UV resistance.  It is an excellent electrical insulator. Used in automotive, housewares and toys.

  • Color: White
  • Temperature Range: -40° to 180° F
  • Tensile Strength: 9,100-9,500 psi (Good)
  • Impact Strength: 2 ft.–lbs./in. (Good)
  • Hardness: Rockwell M70 (Hard)
  • For Use Outdoors: Yes
  • Specifications Met: UL 746C, UL 879, UL 94 HB, UL 972

     

  • Color: Black
  • Temperature Range: -40° to 180° F
  • Tensile Strength: 9,100-9,500 psi (Good)
  • Impact Strength: 2 ft.–lbs./in. (Good)
  • Hardness: Rockwell M70 (Hard)
  • For Use Outdoors: No
  • Specifications Met: FDA Compliant 21 CFR 177.1580, UL 94 HB

Polycarbonate has exceptional impact strength, heat and UV resistance.  It is an excellent electrical insulator. Used in automotive, housewares and toys.

  • Temperature Range: -40° to 180° F
  • Tensile Strength: 8,900-9,500 psi (Good)
  • Hardness: Rockwell R118 (Hard)
  • For Use Outdoors: Yes
  • Specifications Met: UL 94 V-0, UL 972

Polypropylene is noted for its high strength to weight ratio, excellent chemical resistance and high performance in corrosive environments.  Used in pump components, process equipment, storage tanks, valve bodies, and medical devices.

  • Color: Opaque White
  • Temperature Range: 0° to 180° F
  • Tensile Strength: 4,060-4,930 psi (Poor)
  • Impact Strength: 0.9-1.9 ft.–lbs./in. (Poor)
  • Hardness: Rockwell R80-R90 (Hard)
  • For Use Outdoors: No
  • Specifications Met: ASTM D4101, FDA Compliant 21 CFR 177.1520, UL 94 HB

PVC is a normal impact and high corrosion resistant plastic.  It is an excellent electrical insulator. Its high strength-to-weight ratio, cost efficiency and ease of fabrication makes it a material of choice.

  • Color: Gray
  • Temperature Range: 0° to 150° F
  • Tensile Strength: 7,000-7,800 psi (Good)
  • Impact Strength: 0.7-3 ft.–lbs./in. (Poor)
  • Hardness: Rockwell R110-R120 (Hard)
  • Specifications Met: UL 94 V-0
  • For Use Outdoors: No

UHMW-PE has a low-friction surface that prevents sticking and binding.  It is a tough, impact and wear resistant material that can handle scuffs, scrapes, and strikes that other plastics can’t.

  • Temperature Range: -40° to 180° F
  • Tensile Strength: 4,350-5,800 psi (Poor)
  • Impact Strength: 16.8 ft.–lbs./in. (Excellent)
  • Hardness: Durometer 65D-67D (Medium)
  • For Use Outdoors: No
  • Specifications Met:
    White: ASTM D4020, ASTM D6712, FDA Compliant 21 CFR 177.1520, UL 94 HB
    Black: ASTM D4020, ASTM D6712, FDA Compliant 21 CFR 177.1520, FDA Compliant 21 CFR 178.2010, FDA Compliant 21 CFR 178.3297, UL 94 HB

Standard Materials: METAL

The most widely used aluminum, 6061 is fabricated into everything from pipe fittings and containers to automotive and aerospace parts.  It is strong and corrosion resistant.

  • Yield Strength: 35,000 psi
  • Hardness: Brinell 95 (Soft)
  • Temper: T6 or T6511
  • Specifications Met: ASTM B221 or ASTM B209

With the highest lead content of all the brass alloys, 360 offers the best machinability.  Often called free-machining and free-cutting brass.  It’s commonly used for gears, pinions, and lock components.

  • Yield Strength: 15,000 psi
  • Hardness: Rockwell B35 (Soft)
  • Temper: H02 (1/2 Hard)
  • Heat Treatable: No
  • Specifications Met: ASTM B16

A lead-free alternative to 12L14 carbon steel, 1215 carbon steel contains the same amount of sulfur and phosphorus for excellent machinability.  It’s often used for shaft couplings, studs, and pins.  For added wear resistance, you can harden its surface with heat treating.

  • Yield Strength: 60,000 psi
  • Hardness: Rockwell B85 (Medium)
  • Heat Treatable: Yes
  • Max. Hardness After Heat Treatment: Not Rated
  • Fabrication: Cold Worked
  • Specifications Met: ASTM A108

The lead additive acts as a lubricant, which allows 12L14 carbon steel to withstand very fast machining. It’s used to fabricate a wide variety of machine parts.

  • Yield Strength: 60,000 psi
  • Hardness: Rockwell B85 (Medium)
  • Heat Treatable: Yes
  • Max. Hardness After Heat Treatment: Rockwell C60
  • Specifications Met: ASTM A108

Also known as mild steel, low-carbon steel is easy to machine, form, and weld. It’s widely fabricated into parts that don’t require high strength, such as fixture clamps and mounting plates.

  • Yield Strength: 20,000 psi to 60,000 psi
  • Hardness: Not Rated
  • Heat Treatable: Yes
  • Max. Hardness After Heat Treatment: Not Rated

Widely used for fabricating fittings and fasteners, 303 stainless steel machines quickly without sticking to cutting tools. It maintains its corrosion resistance in temperatures up to 1500° F.

  • Hardness: Rockwell B80 to B85 (Medium)
  • Heat Treatment: Annealed (Softened)
  • Heat Treatable: No
  • Specifications Met: ASTM A895 or ASTM A582

From cookware to chemical-processing equipment, 304 stainless steel is a good all-around choice for a wide range of applications. It maintains its corrosion resistance in temperatures up to 1500° F.

  • Yield Strength: 30,000 psi
  • Hardness: Rockwell B75-90 (Medium)
  • Heat Treatment: Annealed (Softened)
  • Heat Treatable: No
  • Specifications Met: ASTM A240 or ASTM A276

Often used for dies, punches, and gauges, O1 tool steel is an oil-hardening material that resists wear and abrasion.

  • Yield Strength: 50,000 to 60,000 psi
  • Hardness: Rockwell B85 to B90 (Medium)
  • Heat Treatable: Yes
  • Max. Hardness After Heat Treatment: Rockwell C62 to C65

A2 tool steel is more wear resistant than O1 and it keeps a sharper cutting edge. This air-hardening material is widely used for punches, broaches, and dies.

  • Hardness: Rockwell B90 (Medium)
  • Heat Treatable: Yes
  • Max. Hardness After Heat Treatment: Rockwell C62 to C65

Radii

Sharp inside corners on a part will have a radius (be rounded) as a natural result of the CNC milling process.

Maximum Size

Maximum part size: 10 in. x 7 in. (254 mm x 178 mm)

Maximum depth: ranges from 0.75 in. to 3.75 in. (19 mm to 95 mm). The maximum size which can be milled from either side of the part is 2 in. (51 mm).

Minimum part size: 0.25 in. x 0.25 in. x 0.25 in. (6.4 mm x 6.4 mm x 6.4 mm)

Surface Finishes

All machined parts are left as-milled, which typically means they show visible tool marks. If you require additional finishing, please be sure to specify when requesting a quote.

Text on Parts

Recessed text should have a minimum stroke width of 0.020 in. (0.5 mm). The spacing between characters on raised text should be 0.020 in. (0.5 mm) or greater. If your design permits it, opt for raised text versus recessed.

Thickness

The CNC machining process typically requires nominal part thickness to be larger than 0.040 inc. (1 mm). Parts may be as thin as 0.020 in. (0.5 mm) in regions as long as the nominal part thickness stays above 0.040 in. (1 mm). Features thinner than 0.020 in. (0.5 mm) typically do not survive the machining process.

Threaded Holes

We currently support UNC and UNF threads from #2 up to 1/2 in. and metric threads from M2 to M12.

Tolerances

In general, tolerances of ±0.005 in. (0.13 mm) are expected and achieved.

CNC Design Considerations

CNC Machined Prototype Quote Submission

You will receive an e-mail confirming receipt of your request.

Files up to 20MB may be sent via e-mail to:  Sales@Versadyne.net