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A guide to chemical finishes for CNC machined parts

Fast Radius — Wed, 16 Nov 2022 16:00:00 +0000

All post-processing increases part costs and production timelines, but the right surface finish has the potential to bring your design vision to life. Metal finishing for CNC machined parts typically encompasses a variety of mechanical processes, such as tumbling, brushing, and bead blasting, but metal parts may also be treated with chemical finishes such as passivation and zinc plating.

Amongst many useful results, chemical finishing can remove blemishes from a part, alter its conductivity levels, extend its lifespan, and even increase its resistance to wear and corrosion. Chemical finishes have an array of industrial applications: in the aerospace industry, for example, companies use chemical finishes to increase parts’ durability, improve thermal stability, and slow oxidation. In the consumer goods industry, chemical finishes can be found in the production of everything from enclosures and casings to sporting equipment.

While there are plenty of chemical finishes available, they aren’t necessarily interchangeable between materials. In fact, every chemical finish is typically compatible with specific materials and offers its own advantages and disadvantages. In this guide, we’ll explore several common chemical finishing processes so that you can decide which will work best for your CNC manufacturing project.

Choosing your chemical finish

When choosing a chemical finish for your part, you’ll need to think about both compatible materials and end use. This means considering an array of contextual factors, including:

The environment your part will be used in
Whether it requires conductive or insulating properties
How much weight it will need to bear
How much wear it will need to withstand
Tolerance requirements
Color and transparency requirements
Surface finish standards
Any other relevant or desired properties.

To help you evaluate your options, here are some common chemical finishes and their compatible materials:

Chemical Finish	Compatible Materials
Anodizing	Aluminum, titanium, and other non-ferrous metals
Passivation	Stainless steel
Black oxide	Steel, stainless steel, copper, and other metals
Chem film (chromate conversion coating)	Aluminum
Electropolishing	Aluminum, steel, stainless steel, copper, titanium, brass, bronze, beryllium, and other metals
Electroplating with cadmium, chrome, copper, gold, nickel, silver, tin	Aluminum, steel, and other metals
Chrome plating (a type of electroplating)	Aluminum, steel, stainless steel, nickel alloys, titanium, copper, and other metals
Polytetrafluoroethylene (Teflon) coating	Aluminum, steel, and other metals
Electroless nickel plating	Aluminum, steel, and stainless steel
Zinc plating	Steel

Let’s take a closer look at these chemical processes, how they work, and how they might benefit your project.

Anodizing

A popular aluminum finishing option, anodizing thickens the natural oxide layer on part surfaces, creating an anodic oxide film that confers increased protection and improved aesthetics. In the case of aluminum, to form the anodized protective layer, you’ll need to bathe your part in an acid electrolyte bath and then apply a cathode (a negatively charged electrode) to cause the solution to release hydrogen. At the same time, the aluminum part (the positively charged anode) will release oxygen, forming a protective oxide layer on its surface. After a part has been anodized, its surface will have microscopic pores which must be sealed with a chemical solution to prevent corrosion and any build up of contaminants.

Anodized parts are durable and resistant to corrosion and abrasion, which can reduce maintenance costs down the line. The anodized layer is electrically non-conductive and is fully integrated with the aluminum substrate, so it won’t chip or flake away like plating and paint often do. In fact, in addition to sealing, the porous anodized layer can be painted or dyed, and since anodized finishes are non-toxic and chemically stable, they’re also more environmentally friendly. Anodizing isn’t just a finish for aluminum: the process is also possible for titanium and other non-ferrous metal parts.

There are three different types of anodization:

Type I (chromic acid anodizing) results in the thinnest oxide layer, which means it won’t change your part’s dimensions. Type I anodized elements will appear grayer in color and won’t absorb other colors well.
Type II (boric-sulfuric acid anodizing) has better paint adhesion and is slightly thicker than Type I. With Type II anodizing, you can easily create anodized parts that are blue, red, gold, black, or green.
Type III (hard sulfuric acid anodizing) is the most common form of anodizing. It has the clearest finish, which means it can be used with more colors. It’s worth noting that Type III anodizing results in a slightly thicker finish than Type II anodizing.

The increased durability, abrasion resistance, and corrosion resistance of anodized parts, and the high level of dimensional control that the process offers, makes anodizing particularly popular in aerospace and construction. Beyond those industries, anodized metal components are found in a wide variety of applications including curtain walls, escalators, laptops, and more.

Despite its broad applications, there are drawbacks to anodization:

Anodizing metal will change the dimensions of your part, so you’ll need to consider the oxide layer when determining dimensional tolerances or use chemical or physical masks to ensure specific areas of your part remain untreated.
It can be challenging to achieve a true color match if your anodized components aren’t treated in the same batch. Color fading may also occur.
Anodizing a metal part will increase its electrical and thermal resistance. In some cases, this might be the intention, but in others, you may need to use a mask to ensure your part retains its full conductivity in certain sections.
Anodizing will increase your part’s surface hardness.

Passivation

This popular metal finishing process prevents corrosion in stainless steel parts, helping them retain their cleanliness, performance, and appearance. Not only will passivated parts be far more resistant to rust, and thus better suited to use outdoors, they’ll also be less likely to pit, last longer, be more aesthetically pleasing, and more functional. Accordingly, passivation is used across a variety of industries, from the medical industry where sterilization and longevity are key, to the aerospace industry where businesses seek high steel quality and tight dimensional tolerances.

Passivation involves the application of nitric or citric acid to a part. While nitric acid has traditionally been the typical choice for passivation, citric acid has recently increased in popularity because it can produce shorter cycle times, and is safer and more environmentally friendly. During the passivation process, parts are submerged in an acid-based bath to remove any iron and rust from their surfaces without disturbing the chromium. The application of acid to stainless steel removes any free iron or iron compounds from its surface, leaving behind a layer composed of chromium (and sometimes nickel). After exposure to the air, these materials react with oxygen to form a protective oxide layer.

It’s important to bear in mind that passivation can extend part production time. Before a part can be passivated, it must be cleaned to remove any greases, dirt, or other contaminants, and then rinsed and soaked (or sprayed). While submersion is the most common passivation method because it offers uniform coverage and can be completed quickly, an acidic spray may be used as an alternative.

Black oxide coating

A finish for ferrous metals like steel, stainless steel, and copper, the black oxide coating process involves immersing parts in an oxide bath to form a layer of magnetite (Fe₃O₄), which offers mild corrosion resistance.

There are three types of black oxide coating:

Hot black oxide: The hot black oxide coating process involves dipping a part into a hot bath of sodium hydroxide, nitrites, and nitrates in order to turn its surface into magnetite. After bathing, parts will need to be submerged in alkaline cleaner, water, and caustic soda, and then coated with oil or wax to achieve the desired aesthetic.
Mid-temperature black oxide: Mid-temperature black oxide coating is very similar to hot black oxide coating. The main difference is that coated parts will blacken at a lower temperature (90 – 120 °C). Since this is below the boiling point of the sodium and nitrate solution, there’s less need to worry about caustic fumes.
Cold black oxide: While hot and mid-temperature black oxide coating involves oxide conversion, cold black oxide relies on deposited copper selenium to alter a part. Cold black oxide is easier to apply but rubs off more quickly and provides less abrasion resistance.

Parts that have received black oxide coating will have greater corrosion and rust resistance, be less reflective, and will have much longer life cycles. The oil or wax coating will add water resistance and may also make your parts easier to clean by preventing harmful substances from reaching the metal interior. Black oxide coating will also add thickness, making it ideal for drills, screwdrivers, and other tools that require sharp edges that won’t dull over time.

Chem film

Chem film, also known as chromate conversion coating, or by its brand name Alodine®, is a thin coating typically used on aluminum (although it can be applied to other metals) to prevent corrosion and improve adherence of adhesives and paints. Chem film finishes often have proprietary formulas, but chromium is the main component in every variety. A chem film finish can be applied via spraying, dipping, or brushing, and, depending on product and formula, may be yellow, tan, gold, or clear in color.

While other finishes reduce thermal and electrical conductivity, chem film finishing allows aluminum to maintain its conductive properties. Chem film is also relatively cheap and, as noted, provides a good base for painting and priming (for additional time-saving benefits). Since it’s prone to scratches, abrasion, and other superficial damage, however, chem film isn’t ideal for projects in which aesthetic appearance is a top priority.

Electropolishing

Electropolishing is an electrochemical finishing process commonly used to remove a thin layer of material from steel, stainless steel, and similar alloys. During the electropolishing process, a part is submerged in a chemical bath and an electric current is applied to dissolve its surface layer. Various parameters affect the part’s finish, including the chemical composition of the electrolyte solution, its temperature, and the part’s exposure time.

Electropolishing generally removes between 0.0002 and 0.0003 inches from an object’s surface, leaving smooth, shiny, and clean material behind. Other benefits of electropolishing include improved corrosion resistance, increased part longevity, improved fatigue strength, a lower coefficient of friction, reduced surface roughness, and the elimination of surface defects such as burrs and micro-cracks.

Electropolishing is compatible with steel, stainless steel, copper, titanium, aluminum, brass, bronze, beryllium, and more. It’s worth noting that electropolishing is faster and cheaper than manual polishing, though it still takes time and won’t remove 100% of rough surface defects.

Electroplating

Electroplating is effectively the reverse of electropolishing. Instead of removing a layer of metal to achieve a finished surface, electroplating deposits an additional outer layer, increasing a part’s thickness. Compatible with cadmium, chrome, copper, gold, nickel, silver, and tin, electroplating creates smooth parts that experience less wear and tear over time thanks to their additional protection from corrosion, tarnishing, shock, and heat. Electroplating can increase adhesion between the base material and its additional outer coating, and, depending on the type of metal used, can make your part magnetic or conductive.

In contrast to other CNC machining finishes, electroplating isn’t particularly eco-friendly since it creates hazardous waste that can seriously pollute the environment if disposed of improperly. Electroplating is also relatively costly, as a result of the metals and chemicals (and other necessary materials and equipment) that it requires, and can be time-consuming, especially if a part requires multiple layers.

Chrome plating

Chrome plating, or chromium plating, is a type of electroplating that involves adding a thin layer of chromium to a metal part to increase its surface hardness or resistance to corrosion. The addition of a chrome layer can make cleaning a part easier and improve its aesthetics, and nearly all metal parts can be chrome plated, including aluminum, stainless steel, and titanium.

The chrome plating process generally involves the degreasing, manual cleaning, and pretreatment of a part before it is placed in a chrome plating vat. The part must then stay in the vat long enough for the chrome layer to reach a desired thickness. Since the process consumes electricity, and involves multiple steps, chrome plating is a relatively expensive finishing process.

Polytetrafluoroethylene (Teflon) coating

Polytetrafluoroethylene (PTFE) coating, commonly known as Teflon, is available in powder and liquid forms, and is used across the industrial landscape. Some PTFE applications only require one coat, but others need both a primer and a topcoat to ensure maximum protection. The finish can be applied to a range of metals including steel, aluminum, and magnesium.

PTFE-coated parts have non-stick surfaces, a low coefficient of friction, and are highly resistant to abrasions. Since PTFE coating has low porosity and surface energy, coated parts will be resistant to water, oil, and chemicals. PTFE can also withstand temperatures up to 500°F, can be easily cleaned, and offers great electrical insulation and chemical resistance.

Due to its chemical resistance and non-stick properties, PTFE is often used to coat fuel pipes and to insulate circuit boards in computers, microwaves, smartphones, and air conditioners. It is also commonly used to coat medical tools and equipment, and cookware. Although it is popular across industries, the PTFE coating process is relatively expensive and isn’t as long-lasting as other chemical finishing options.

Electroless nickel plating

Electroless nickel plating refers to the addition of a protective layer of nickel-alloy to metal parts. In contrast to the electroplating process, which involves an electric current, electroless nickel plating involves the use of a nickel bath and a chemical reducing agent like sodium hypophosphite to deposit a layer of nickel-alloy (often nickel-phosphorus) onto parts. The nickel-alloy deposits uniformly, even on complex parts with holes and slots.

Parts finished with nickel plating have increased resistance to corrosion from oxygen, carbon dioxide, salt water, and hydrogen sulfide. Nickel-plated parts also have good hardness and wear resistance and, with additional heat treatment, can become even harder. Electroless nickel plating is compatible with a variety of metals, including aluminum, steel, and stainless steel.

Electroless nickel playing has its challenges. Common problems include the build up of contaminants in nickel baths, rising phosphorus content, and subsequent reductions in plating rates. Additionally, the wrong temperature or pH level can create coating quality issues like pitting, dullness, and roughness. Electroless nickel plating isn’t suitable for rough, uneven, or poorly machined surfaces, and parts will need to be cleaned of soaps, oils, and dirt before the plating process can begin.

Different types of electroless nickel plating coatings are categorized by the percentage of phosphorus in the alloy by weight. Different levels of phosphorus content also offer different levels of corrosion resistance and hardness:

Low phosphorus nickel (2 – 4% phosphorus): Low phosphorus electroless nickel has an as-plated hardness between 58 and 62 Rc, and is highly resistant to wear. It has a high melting point and good corrosion resistance when exposed to alkaline conditions. Low phosphorus electroless nickel deposits are compressively stressed and are usually more expensive than medium and high phosphorus nickel.
Medium phosphorus nickel (5 – 9% phosphorus): Medium phosphorus nickel plating offers a middle ground between low and high phosphorus nickel. It is resistant to corrosion in alkaline and acidic environments and has a fast deposition rate (18 to 25 µm per hour). The as-plated hardness of medium phosphorus nickel can be anywhere between 45 and 57 Rc, and the plating can be heat treated to reach 65 to 70 Rc.
High phosphorus nickel (>10% phosphorus): Since high phosphorus deposits of electroless nickel plating are amorphous, parts won’t end up with phase boundaries or grain, increasing their corrosion resistance and making them ideal for use outdoors or in extreme environments. High phosphorus electroless nickel plating also offers ductility, high thickness, and stain resistance, and will make it easier to polish or solder your final product.

Zinc plating

Zinc plating, or zinc chromate, is a popular chemical finish that protects steel parts from moisture and corrosion. Zinc-plated products have increased longevity, improved aesthetic appeal, and a more uniform appearance. Zinc plating can also alter a part’s color to silver-blue, yellow, black, or green. Another significant benefit of zinc plating is its potential to protect a part’s surface for years: even if the coating becomes scratched, the zinc will react to the atmosphere and quickly oxidize. Since zinc is chemically susceptible to acids and alkalis, however, zinc plating may not be sufficient for parts destined for wet or extremely humid environments.

There are a few different types of zinc plating. Electro-galvanization requires an electrical current to coat the part in a thin layer of zinc, whereas hot-dip galvanization requires parts to be submerged in a hot zinc bath. Electro-galvanization is the cheaper process, but hot-dip galvanization is better for parts that will be used in aggressive environments or that will experience a lot of wear.

Following the zinc plating process, parts can undergo a secondary procedure for increased protection and improved performance. The ASTM B633 standard, the most widely used standard for zinc plating, includes four types of zinc plating:

Type I: Type I has no supplementary treatment.
Type II: Type II involves a colored chromate treatment.
Type III: Type III uses a colorless chromate treatment.
Type IV: Type IV uses a phosphate conversion treatment.

Achieving quality finishes with Fast Radius

Chemical finishing offers numerous ways to achieve the surface quality and performance levels that you need for your part, but not every finishing process will be suitable for every material and end-use. To determine which chemical finish is right for your part, you’ll need to have a strong understanding of critical factors, such as how much corrosion, friction, and wear resistance your final part needs, the environment in which it will be used, and its required conductive or insulative properties.

Given the importance of those considerations, it’s worth finding a manufacturing partner to help you select a suitable finish, and ensure that it offers the best quality and cost efficiency possible. At Fast Radius, our expert team of designers and engineers can offer insight not just into the chemical finishing process, but material selection, tooling, and suitable CNC technologies. If you want to know more about the finishing options available for your next CNC machining project, get in touch with us today. If you’re ready to get started, create your Fast Radius account, upload your designs to get an instant quote, and start making new parts and products in just a few simple steps.

Check out our resource center to learn about choosing the best finish for your CNC machined part, measuring and understanding surface finish, and more.

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Exploring the prototyping phases of 3D printing

Fast Radius — Wed, 09 Nov 2022 16:00:00 +0000

Prototyping is an essential part of the product development process, but it isn’t just limited to rapidly-produced proof of concept models. Prototyping also comes in handy throughout various phases of a project’s development, including engineering, quality assurance, focus testing, and marketing.

Prior to the introduction of 3D printing, the production, assembly, and presentation of functional prototypes was a long, expensive, and sometimes impossible process. Today, however, a range of 3D printing technologies has made those processes quicker and easier, with both the cost of part production and assembly times reduced significantly. Even with the benefits that 3D printing brings to the prototyping process, it’s still important to understand how it can be optimized during prototyping, so that your project comes together on time, even when you’re facing a critical deadline.

3D printing prototyping phases explained

Product conceptualization

The product conceptualization phase occurs early in the product development life cycle, and involves the relatively swift creation of a model that conveys a design idea. In this phase, speed is a top priority, which makes 3D printing the perfect technology to bring your designs to life.

During production conceptualization, a 3D printer can be used to quickly build one (or several) prototypes to help sell an idea to internal and external stakeholders, and to develop a sales model. These physical mockups will vary in cost depending on materials used and by production requirements. A prototype printed from polylactic acid (PLA), for example, will cost less than one made from ULTEM (PEI). Similarly, while a prototype printed with a taller layer height will be faster and less expensive to produce than one with a shorter layer height, it will look less polished.

Proof of concept demonstration

Proof of concept prototypes are essentially working models that demonstrate functionality and prove that your design will fulfill its intended purpose.

A proof of concept prototype does not need to be produced with the same aesthetic standard as a finished product. During this phase, the emphasis should be on functionality; to save time and money, you may be able to use off-the-shelf components in your proof of concept model, or make the model with a slightly larger layer size than you would for a more advanced prototype.

While it is possible to use fused deposition modeling (FDM) for proof of concept prototypes, it may be best to use an additive process that offers a little more accuracy, such as Carbon® Digital Light Synthesis (DLS) or HP Multi Jet Fusion (MJF). For some prototyping projects, it may even make sense to look beyond additive and explore different manufacturing processes during the proof of concept phase.

Industrial design implementation

The industrial design implementation phase is when you evaluate the ergonomics, aesthetics, usability, and scale of your prototype so that it will closely simulate your final product.

During this phase, it’s important to use a similar material to your final product in order to better understand its overall ease of use, appearance, and ergonomics. For example, you might use FDM to create parts with the same thermoplastic materials that you would use in the injection molding process so that you don’t need to create an expensive and time-consuming mold but can still get a sense of the look and feel of your final product. Similarly, you might opt to use an HP MJF printer to 3D print a nylon part and coat it with nickel as a finishing process, instead of CNC machining an entirely metal prototype.

Functional testing and feedback

The functional testing and feedback phase is when you create functional prototypes to see if your product will actually work.

Functional prototypes generally require end-use durability and a higher-quality surface than parts produced in earlier prototyping phases, and can be sent out for stakeholder feedback in order to improve designs for your next iteration. A hybrid of proof of concept and industrial design prototypes, functional prototypes can be used to test everything from thermal performance and aerodynamics to mechanical performance and properties. Since stakeholder feedback often leads to additional design revisions, it’s best to create functional prototypes before investing in costly tooling in order to avoid mistakes and modifications that stretch your budget and project timeline.

Pre-manufacturing research modeling

The pre-manufacturing research modeling phase refers to the creation of research prototypes that look and function like the finished product.

Creating research prototypes, enables critical stakeholders and early adopters to experience your product before the final version is released. Pre-manufacturing research prototypes will be more refined than functional prototypes, yet produced in lower volumes than final production runs. Feedback from stakeholders and early adopters during this phase could mean additional design changes.

Pre-manufacturing research prototypes also enable you to assess parts in the context of design for manufacturability (DFM) or assembly, and then optimize your design for high-volume production. Even the slightest change in product design can significantly impact costs, particularly when dealing with high volumes of parts.

The advantages of using 3D printing for prototyping

3D printing has plenty to offer when it comes to prototyping. Not only can you use 3D printed prototypes to better understand the form and function of your part, and to optimize your design accordingly, but you won’t break the bank creating them since there’s less need for expensive tooling than, for example, injection molding.

Speed is a notable advantage of prototyping via 3D printing. Instead of waiting weeks or months for a part (as you might with CNC machining or injection molding), a 3D printed prototype can be in your hands in days or even hours. The pace of 3D printing prototype production enables designers to swiftly move from iteration to iteration until a final design is perfected. 3D printers can also handle complex geometries: whether you’re creating a part with a hollow interior, holes, or moving elements, 3D printing is typically a reliable way to create functional, dimensionally-accurate prototypes.

3D printing technology also offers access to a wide range of industrial materials, from performance-grade thermoplastics to light-sensitive resins. That versatility can open up design possibilities for your prototypes: you could use 3D printing technology to create multi-material parts, for example, or use water-soluble support materials to achieve even more complex geometries.

Tackling the prototyping phases of 3D printing with Fast Radius

While 3D printing offers clear benefits during the various phases of prototyping, it may not make sense for you to invest in a 3D printer yourself. 3D printing requires a significant investment in equipment and materials, and requires a level of additive manufacturing technical expertise that might be similarly costly to acquire. With those considerations in mind, it’s entirely possible to minimize the financial and technical challenges of 3D printing by working with a manufacturing partner.

When you work with Fast Radius, you’ll have access to cutting-edge 3D printing technology, an array of additive materials, and the skills you’ll need to deliver on your vision. Our team of expert designers and additive manufacturing engineers will guide you through the prototyping process, ensuring that you optimize your project for quality and cost during every phase. And getting your prototyping project started is easy: simply create a Fast Radius account and upload your design to get an instant quote.

Additionally, you’ll be able to explore different materials, run DFM checks, and store iterations of your prototype parts in the cloud. If you’re ready to get started but want to find out more about your 3D printing prototyping options, contact us today to speak with one of our experts to get the assistance you need to make your ideas a reality.

Visit our resource center to learn more about 3D printing, including 3D printed lattices, the cost of 3D printing, and more.

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The post Exploring the prototyping phases of 3D printing appeared first on Fast Radius.

Key differences for acrylic and polycarbonate machining

Tyler Vinyard — Wed, 02 Nov 2022 16:00:00 +0000

Acrylic, also known as plexiglass or polymethyl methacrylate (PMMA), and polycarbonate are both lightweight, transparent plastics suitable for manufacturing parts via CNC machining. Acrylic is known for its strength and transparency, making it an excellent alternative to standard glass, whereas polycarbonate is incredibly tough and impact resistant, making it ideal for applications that require clarity as well as increased durability, such as safety glass.

While acrylic and polycarbonate are similar in many respects, there are some important differences between these two common materials that can make one better suited for a particular application over the other, or impact the machining process and thus lead time and cost. In this article, we’ll go over what you need to know about machining acrylic and polycarbonate so that you can select the best manufacturing option for your project and create designs that work with the material you choose.

Machining acrylic and polycarbonate: What you need to know

When it comes to machining acrylic, cast acrylic is often a better choice than extruded acrylic, as the latter is more likely to crack or chip during the machining process. This means that the toolpath strategies sometimes need careful selection to avoid chipping the part. Additionally, since acrylics aren’t very heat resistant, it’s necessary to use a sharp cutting tool in order to obtain a smooth surface finish. Acrylic’s low melting point means that it will also be necessary to use a lower cutting feedrate than other plastics during machining, since higher feedrates will generate more friction and heat, and potentially ruin your part. If necessary, acrylic may be kept in a freezer before machining to ensure that it remains as cool as possible.

With its toughness and impact resistance, polycarbonate is better for machining and is particularly well-suited to CNC milling. However, when machining polycarbonate, the sharpness of the cutting tool is still important, as polycarbonate sheets can melt if too much heat builds up during the machining process. Since polycarbonate is less likely to chip than acrylic, it tends to be easier to machine and allows for more standard toolpath strategies to be used. In addition, because there is a higher temperature working range, more aggressive strategies can be used with a smaller chance of causing issues, potentially saving time and money.

Applications for acrylic and polycarbonate

Both acrylic and polycarbonate are lightweight, machinable, and have unique characteristics that make them suitable for an array of applications across industries.

Acrylic is a popular material within the automotive, construction, and aerospace industries, and is often used for things like dry boxes, lenses, radiation shields, and desiccators. Additionally, its transparency, strength, and high impact resistance make it a great alternative to glass, and you can commonly find it used in greenhouses, aquariums, terrariums, security barriers, and more.

Like acrylic, polycarbonate is popular in the automotive, aerospace, and construction industries, but its resistance to heat and strong dimensional stability make it very popular in the medical industry, as polycarbonate parts can withstand limited autoclaves and irradiation sterilization. Among its more common applications, polycarbonate is often used for point-of-purchase retail displays, face shields, architectural features, clear manifolds, bulletproof windows, and much more.

Pros and cons of using acrylic for your parts

Acrylic offers a range positive attributes, including:

Transparency: Acrylic can allow up to 92% of light to pass through it, making it more transparent than some grades of glass and most other thermoplastics. It can also be colored without sacrificing its transparency, though it’s possible to manufacture more opaque acrylic parts, as well.
Strength: Acrylic is much stronger and more impact resistant than glass. Most grades of acrylic are four to eight times stronger than glass.
Environmental resistance: Acrylic is naturally resistant to scratches, weathering, and UV radiation, making it ideal for outdoor applications.
Chemical resistance: Acrylic is resistant to many chemicals, including alkalis, detergents, cleaners, and dilute inorganic acids.
Moisture absorption: Acrylic has low moisture absorption, which allows it to retain its dimensions when used in outdoor applications.
Compatibility with coatings: Acrylic parts can be coated with anti-static, hard coat, or non-glare layers in order to improve their surface quality, extend their lifespan, and ensure they meet specific requirements.
Affordability: Despite its strength, durability, and clarity, acrylic remains relatively inexpensive to manufacture and machine. For comparison, polycarbonate is about 35 – 40% more expensive.
Color: Acrylic is available in a wide range of colors.

CNC machining acrylic is not without its disadvantages. As previously noted, acrylic is more susceptible to cracking and chipping than polycarbonate, and it’s slightly more difficult to machine, since it will lose structural integrity and begin melting at temperatures over 160°C. When designing acrylic parts for CNC machining, you’ll need to remember that relatively low melting point because it makes the material more susceptible to deformation during the manufacturing process. To avoid the risk of melting, and to achieve a quality surface finish, using a proper feed rate and pass depth is crucial. Similarly, to reduce chatter and achieve quality cuts, acrylic parts should be machined using tools with a short flute length and a cutting depth roughly half the diameter of the bit.

Your product’s intended use will also determine whether acrylic is the best option for your project. For example, acrylic’s extreme biocompatibility makes it a good option for bone implants, dentures, or other skin-contact applications; similarly, its resistance to weather, UV radiation, and scratching make it a good fit for parts which will be used outdoors. On the other hand, acrylic might not be the best choice for food containers that will be exposed to high temperature environments, such as dishwashers or microwaves, since acrylic parts will only maintain their dimensions up to 149°F (65°C), at which point they begin to soften.

Pros and cons of using polycarbonate for your parts

The positives of using polycarbonate include:

Transparency: Polycarbonate is a naturally transparent thermoplastic that can transmit light just as effectively as glass, making it ideal for lenses, lighting, and bulletproof glass. Like acrylic, polycarbonate can be colored without sacrificing its transparency.
Variety: There are several formulations of polycarbonate on the market, including glass-filled and FDA-compliant variants, so it’s likely that you’ll be able to find one that meets your project’s needs.
Strength and impact resistance: Polycarbonate has a tensile strength around 200 times that of glass, and is highly resistant to impact. Accordingly, it’s often used in bullet-resistant glass and protective gear.
Shrinkage and dimensional stability: Polycarbonate will maintain its dimensions under most conditions, and has a low shrink rate of 0.6 – 0.9%.
Environmental resistance: Polycarbonate is naturally resistant to UV radiation and can withstand varying moisture levels and fluctuating temperatures, which makes it an excellent material for outdoor applications and eyewear.
Chemical resistance: Polycarbonate is resistant to many chemicals, including diluted acids, oils, waxes, aliphatic hydrocarbons, alcohols, and greases.
Moisture absorption: Polycarbonate has slightly lower moisture absorption compared to acrylic.
Compatibility with coatings: Like acrylic, polycarbonate components can be coated with anti-static, hard coat, and non-glare layers. Polycarbonate is also compatible with UV and anti-fog layers.
High machinability: Since it’s so durable and tolerant to heat, polycarbonate is easier to machine than acrylic.

While polycarbonate has many positive attributes, there are some disadvantages to using polycarbonate for a CNC machining project, including its high cost and its susceptibility to denting. Additionally, since polycarbonate scratches easily, it’s more likely to require finishing, which is complicated by the fact that only certain finishing processes, such as vapor polishing and coating, work with polycarbonate parts.

Additionally, it’s important to note that polycarbonate parts are also prone to developing sinks or voids in thicker sections. To prevent this, it’s best to break thicker elements down into smaller, thinner sections to be assembled later. It’s easy to remember this tip by keeping costs in mind — machining a thick part out of a single block of polycarbonate will typically be more expensive than working with smaller pieces due to the cost of the raw materials and the machining time.

Finishing options for acrylic and polycarbonate

There are several finishing options available for acrylic and polycarbonate, including some that will help your parts look and feel ready for end-use applications and even improve clarity:

As-machined finish: The standard and most economical finish, ‘as-machined’ or ‘as-milled’ means that no additional post-processing is applied to the part. As-machined parts have tight dimensional finishes and may represent a faster, more affordable manufacturing option. In some cases, as-machined parts may have small but visible surface tool marks, blemishes, or scratches.
Bead blasting: An economical finish that creates a uniform appearance, bead blasting tends to leave a dull or satin finish and is effective for removing tool marks and surface blemishes.
Vapor polishing: This finishing option uses solvent vapor to transform matte or opaque surfaces into smooth, high gloss, or optically clear surfaces. Vapor polishing is often used on parts where rough surfaces are unacceptable or where clarity is paramount.

With sufficient care during the cutting process, machined surfaces of acrylic and polycarbonate parts will typically be translucent, but can become nearly opaque if the material melts. Should melting occur, it may be possible to address surface opacity with post-processing options such as vapor polishing. However, it’s worth noting that as-machined finishes for acrylic and polycarbonate parts will not be optically clear, although it may be possible to achieve optical clarity if diamond tooling is used, but this must be specifically requested during the quoting process, as it will significantly add to cost.

Bottom line: Comparing acrylic and polycarbonate for machining

Special care should be taken with designs that include machined acrylic due to the increased likelihood of stress cracking. With this in mind, it’s advisable to use razor-sharp cutting tools to avoid melting the acrylic or causing cracking; diamond cutters yield the best surface finish, though carbide cutters are much more affordable. It will also be necessary to use a relatively fast feed rate to prevent the acrylic from melting, but remember that going too fast can cause extreme cutting pressure and breakage.

While polycarbonate is generally better suited to machining thanks to its rigidity, toughness, durability, and higher melting point, the trade-off is that polycarbonate is less transparent than acrylic. However, if you need to create specific-use parts, such as protective gear, fuse boxes, or large, tough components, transparency may not be an issue. On the other hand, if you’re designing a product for which transparency is a top priority, taking the extra effort to machine acrylic may be worth it.

Bringing your part designs to life with Fast Radius

Selecting a suitable material for your manufacturing project can be the difference between success and failure. While we’ve explored the positives and negatives of acrylic and polycarbonate, it’s worth remembering that they’re not your only options. Numerous CNC machining materials may be compatible with your part’s design and intended application, and choosing the right one can be a complicated process.

Fortunately, a manufacturing partner like Fast Radius can reduce that complexity and address the challenges certain materials present. Beyond helping you decide whether acrylic, polycarbonate, or another material will work best for your part, our team can offer access to the tools and expertise you’ll need to ensure production runs as smoothly and cost-efficiently as possible. And getting your project started is simple: just create a Fast Radius account and upload your designs to get a quote for your parts instantly. Or, to learn more about how we can make your project possible, contact us today.

Check out our resource center for more information about CNC machining, including the differences between 3-axis and 5-axis machining, achieving tighter tolerances, and more.

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The top challenges in additive manufacturing and how to overcome them

Nicholas Kavanau — Wed, 26 Oct 2022 16:00:00 +0000

3D printing, also known as additive manufacturing, is a relatively new technology, but it has already come a long way. Since its invention in the 1980s, 3D printing has become increasingly prevalent in the manufacturing industry, so much so that, in 2021, the global 3D printing market was valued at $12.6 billion, and expected to grow to $34.8 billion by 2026.

Although companies like Adidas and Rawlings have used 3D printing technology to create innovative new products, additive manufacturing continues to face adoption challenges at the industrial scale. Research suggests that 63% of enterprises that use additive manufacturing only use the technology for prototyping purposes, and just 21% use it to produce items that can’t be manufactured via other methods.

While additive manufacturing has clear benefits, including helping ease some of the COVID-19 supply chain strain by enabling companies to manufacture parts closer to end-users, many of the technology’s pre-pandemic challenges remain.

Common challenges in additive manufacturing

Production-grade 3D printers are much cheaper than industrial CNC machines or injection molding machines, but additive manufacturing equipment can still be costly. In fact, in a survey by Stratasys, 25% of respondents identified equipment costs as the top challenge when using additive manufacturing. That response is hardly surprising: saving up for the upfront cost of a 3D printer can take time, and most businesses need more than one to handle the volume of orders they receive, which means investing even more money. Some companies simply cannot justify the capital expenditure.

Then, there are the manufacturing and processing costs themselves. In the same Stratasys survey, 16% of respondents said the manufacturing costs associated with additive manufacturing were a top concern. While 3D printers are very autonomous, they still need someone to send the digital file to the printer, ensure the printer is configured correctly, and start the printing process. With multi-material fused deposition modeling (FDM) prints, someone may need to be on hand to swap filaments mid-print and, depending on the materials and printer being used, adjust the nozzle, print speed, retraction settings, and bed temperature. Finally, once a print is done, someone will need to remove any support structures and process the part to achieve a quality surface finish.

Beyond manufacturing and processing costs are additive equipment maintenance costs. 3D printers can break down without proper maintenance, leaving companies without new parts for days (or even weeks) as they wait for replacement parts to arrive. For FDM printers, maintenance can take the form of routinely adjusting belt tension and removing any accumulated plastic from the nozzle. Multi Jet Fusion (MJF) printers require regular printhead and heating lamp maintenance, which can cost thousands of dollars per year, and stereolithography (SLA) printers require regular resin tank maintenance or even replacement. Over time, these maintenance costs can certainly add up.

Additive manufacturing also presents challenges when prints are complete. Most 3D printed parts require some form of post-processing, which takes time and increases the overall labor and overhead costs per unit. For example, SLA parts are covered with viscous excess resin straight out of the printer, and need to be washed in a solvent. FDM parts often require sanding or vapor smoothing due to prominent layer lines or surface blemishes left behind by support structures. With those issues in mind, it’s hardly surprising that 9% of survey respondents named post-processing requirements as a top challenge to additive manufacturing.

It’s also worth noting that additive manufacturing is a much younger technology than traditional manufacturing methods. While injection molding and CNC machining have been used for decades, and already have a large database of compatible materials as well as globally-accepted material standards, additive manufacturing has a more limited selection of materials and fewer established material standards.

Fortunately, additive manufacturing is becoming more popular, and more businesses are investing in developing, standardizing, and qualifying additive materials. In fact, one of the major trends in additive manufacturing in 2021 was the introduction of novel additive materials. Eventually, this research will enable manufacturers to close the gap between additive manufacturing and other technologies. The establishment of globally accepted standards in various industries will also help additive manufacturing gain a stronger foothold in the manufacturing landscape.

Technical challenges to additive manufacturing

Compared to injection molding and CNC machining, additive manufacturing may have lower process predictability and repeatability. For example, additively manufactured parts often go through post-processing to improve their surface finish which, when not controlled properly, is prone to human error and can result in components that can’t meet tight tolerance requirements. This issue represents a challenge when it comes to using additive manufacturing within industries that require extremely high levels of accuracy, such as the aerospace or automotive sectors.

Even though additive manufacturing enables companies to print complex objects without additional assembly, post-processing techniques can lengthen turnaround times and stretch budgets. Furthermore, companies would likely need to invest in inspection and quality control resources to ensure that 3D printed parts comply with any required specifications.

Operational and organizational challenges with additive manufacturing

As a relatively new technology, additive manufacturing also faces operational and organizational challenges. Not only is there no precedent for adopting additive manufacturing at the operational level, but there are a lack of business- and cost-calculation models based on the technology. Many businesses are also wary of using 3D printing because they are uncertain about the ownership of digital designs.

Adding to those challenges, there are few dedicated educational tracks specifically for careers in additive manufacturing, which has resulted in a shortage of skilled personnel with deep knowledge of the technologies and processes. Those factors, combined with the typically limited knowledge of additive technologies in companies that do not specialize specifically in additive manufacturing, mean that many customers aren’t sure where it can add value to their business, so — often to their own detriment — they avoid it altogether.

Solving challenges by working with an experienced additive manufacturing partner

If you aren’t quite sure how to incorporate additive manufacturing into your business, can’t figure out how to design for 3D printing, or aren’t ready for the investments and technical challenges that come with having 3D printers of your own, it’s best to work with a manufacturing partner. An experienced 3D printing partner can help you overcome many of the top challenges associated with additive manufacturing, including upfront equipment costs, inconsistent results, and a lack of 3D printing knowledge. Working with a partner can also give you access to more additive materials and a more comprehensive range of post-processing options.

When you work with Fast Radius, we can provide insight into the design and material selection processes for additive manufacturing technologies, and even identify cost-saving opportunities to help you maximize your savings and profits. And with Fast Radius’ cloud-based software, you can detect design pitfalls with automated design for manufacturability (DFM) analysis, making it easier to iterate on your designs, bring them to life, and realize the benefits of additive manufacturing within your organization. How can you get started? Simply create an account and upload your part files or contact us to speak with an additive manufacturing expert today.

Check out our resource center to learn more about additive manufacturing, including 3D printing layer height, how additive manufacturing can help solve supply chain woes, and more.

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Design tips for low-volume CNC machining production runs

Fast Radius — Wed, 19 Oct 2022 16:00:00 +0000

In the manufacturing business, more money put into production generally means less profit or higher prices for customers. But careful planning and informed decision making about your design will help save time and money during the CNC machining process.

CNC machining costs can be divided into two main buckets: non-recurring costs and piece costs. Non-recurring costs refer to all of the upfront costs required to get any production run (large or small) off the ground; these costs are amortized over the production quantity. Piece costs are expenses associated with each individual part, and scale with quantity. The bottom line cost to manufacture a single part, taking into account all cost buckets, is often referred to as the fully burdened part cost.

To put this in mathematical terms:

Fully Burdened Part Cost = Non Recurring Costs / Quantity + Piece Costs

Non recurring costs include:

Part design
Planning (manufacturing process, inspection, etc.)
CAM programming
CMM programming
Workholding, fixtures, gauges, and tooling identification and sourcing

Piece costs include:

Machine time
Labor time (loading and unloading parts)
Consumable tooling
Raw material
Cleaning, deburring, and finishing
Manual inspection

Following the equation above, in lower volume runs, non-recurring costs are amortized over fewer parts, which means the expense is higher per part. For example, if the non-recurring costs for a job are $5,000, and the production quantity is 100 parts, then each part will have a burden of $50 for non-recurring expenses. On the other hand, if that same job is ordered for a quantity of 200 parts, this would result in a non-recurring burden of just $25 per part, a potentially significant cost delta. The good news is that you can minimize CNC machining costs for shorter production runs by optimizing your part designs.

Design tips for short production runs

To maximize your time and budget, try these design tips for short production runs:

Use standardized, simple designs

Keep your design as simple and standardized as possible. Overly complicated part designs can require multiple manual rotations and repositions, more expensive CNC systems, or specialized tools. With this in mind, it may be worthwhile to break up a complex piece into simpler components that can be assembled later.

You’ll also want to:

Design standard-sized holes: The deeper the hole, the more complex the metal chip evacuation process, and the more expensive your part. Try to make each hole’s depth no more than five to six times the drill’s diameter to ensure your machinist can quickly evacuate the metal chips. Also, make sure to use standard drill sizes when designing your holes or you may end up needing to purchase a custom tool, which can drive up costs and overall production time further.
Use standard threads: As with drill sizes, using standard thread depths and diameters can save time and money. In practice, this means simply using an existing thread class instead of creating a custom thread via CNC machining or 3D printing. Try to use the H2 thread tolerance, since H3 is tighter and more expensive to create. Also, it’s best to keep your thread depth no deeper than required by your part’s functional and structural specifications.
Design with standard stock sizes in mind: You can also cut costs and machine times by designing your parts to align with standard stock sizes. Instead of ordering a larger piece of material only to have to machine it down, your machinist will be able to buy a standard stock piece and then make few (if any) changes before starting on your part. Beyond choosing standard stock sizes, it’s also a good idea to allow a large enough tolerance so that the outside of the part does not need to be machined.
Use loose tolerances: Tight tolerances can require specialized manufacturing processes or secondary operations, and can increase set-up, machining, and inspection time and cost. With that in mind, your part’s tolerances should only be as tight as required by functional and structural constraints.

Avoid thin walls, tall walls, and narrow pockets

CNC machining can be a delicate and time-intensive operation, especially if you have thin walls, tall walls, or narrow pockets.

Since they can increase the risk of cutter deflection, deformation, compromised surface finishes, and part failure, and make it difficult to meet specified tolerances, thin walls are generally less stable and more expensive to machine. Beyond those considerations, your machinist may need to take numerous passes over a part to create a thin wall without accidentally fracturing or snapping it with excessive vibrations, which will, of course, further drive up machining times and costs.

There are options for addressing the increased machining times, higher production costs, and fracture risks associated with thin walls. For example, if you have a metal part, try to design walls that are at least 0.8 mm thick. For plastic parts, try to aim for walls at least 1.5 mm thick. Similarly, you’ll want to avoid including tall walls, deep cavities, and narrow pockets in your part, since these features require longer cutting tools and the removal of more waste material. Like the problems associated with thin walls, these issues can lead to increased cutting tool deflection, chatter, inaccuracies, reduced tool life, and sub-par surface finishes, all of which drive up the final part cost.

Avoid unnecessary text or finishing processes

Adding text to your part will enable you to clearly number components, include a description, or apply a company logo. While machined text looks aesthetically pleasing, and can be functionally useful, it’s an expensive and time-consuming process since you’ll need to trace each character with a small ball end mill or engraving tool. Unfortunately, including raised text on a part is even slower and costlier since even more material will need to be milled away from the part to achieve the effect.

As an alternative to machining, if your part requires text, lettering, or a logo, you may be able to save time and money with a post-production surface finishing method. For example, silk screening, laser marking, rubber ink stamping, and painting will all enable you to add text to your parts faster than direct engraving. Of course, given that adding any CNC finishing process will increase your parts’ turnaround time and overall costs, it’s best to avoid text and other non-critical finishing processes whenever possible.

Choose the proper material

Material selection is important in both long and short production runs since using the wrong metal or plastic for your parts can drastically increase project costs. Some materials are more difficult to machine than others, which means longer turnaround times and higher machining costs. Even if two materials are equally machinable, the chances are that one will be more expensive than the other.

For example, while titanium is ideal for aerospace applications, it’s expensive and difficult to machine. On the other hand, softer, less costly metals, such as aluminum, are easier to machine and strong enough for everything from airplane parts to architectural components. Similarly, if you want to create a plastic part but don’t require the strength or high heat resistance of polyetheretherketone (PEEK), you can save money by using acrylonitrile butadiene styrene (ABS) or another high-performance engineering thermoplastic.

To put it simply, if you don’t really need the properties of an expensive and/or rare material, you should use a less expensive and/or more common material. As an added benefit, using a more readily available material also likely means a reduction in your parts’ overall lead time. It’s worth applying this mentality during the prototyping phase, too; for example, if you only need to create a proof-of-concept model, you should use the least expensive plastic that will still demonstrate the feasibility of your idea.

Additive manufacturing as an alternative for short production runs

While designing with CNC machining lead times in mind can help reduce turnaround and cut costs, depending on your material requirements and the size of your run, additive manufacturing might represent a better option

In contrast to CNC machining, which is a subtractive process that involves cutting away material to shape a final product, the additive manufacturing process builds parts layer by layer. Additive manufacturing is typically far less labor-intensive than CNC machining, sometimes only requiring limited mid-production repositioning and limited post-processing to enhance a part’s functionality, or to achieve a desired finish. Like CNC machining, additive manufacturing can be used to make metal parts, but plastic additive manufacturing is far more common. In fact, many of the plastics used in additive manufacturing are mechanically equivalent to those used in injection molding.

Generally, additive manufacturing is a better choice for extremely low-volume production runs or for projects in which finished parts or prototypes must be delivered fast, and where tolerance requirements are not tight. By contrast, CNC machining is more appropriate for low-volume production runs with part quantities in the higher double digits or low hundreds, or in projects that have high tolerance requirements.

Working with an experienced manufacturing partner

Each of our design tips for short production runs can help you ensure that your production process is as smooth, cost-efficient, and fast as possible. However, there’s a lot to keep track of when optimizing parts for low-volume production, so working with a trusted manufacturing partner is also a valuable opportunity to take some of the weight off your shoulders.

From design through fulfillment, when you work with Fast Radius, our team of experienced engineers will provide you with the support you need to make your project possible. Our cloud-based tools are designed to help you pinpoint design flaws, determine optimal order quantities, and find the right material for your part’s specific application. Simply create an account and upload your part files. We can generate instant quotes for both additive manufacturing and CNC machining projects, which means you can get started making your new parts and products today.

Check out our resource center to learn more about manufacturing, including the CNC material selection process, post-processing for rust and corrosion prevention, how to streamline the CNC machining process, and more.

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Achieving food safety standards with additive manufacturing

Fast Radius — Wed, 12 Oct 2022 16:00:00 +0000

Additive manufacturing, also known as 3D printing, has become an increasingly popular manufacturing method across many industries, from the automotive industry to the medical industry. Over the last few years, there have been several advancements in 3D printing technology, allowing manufacturers to create increasingly complex and durable components that are on par with those made via CNC machining or injection molding.

Additive manufacturing has also had a significant impact on the food industry, which has strict requirements to ensure that the materials which come in contact with food are safe for people.

Is additive manufacturing food-safe?

3D printed parts can be food-safe and meet Food and Drug Administration (FDA) and U.S. Department of Agriculture (USDA) regulations, as long as specific steps and precautions are taken. To ensure your parts are safe for use with food, you’ll want to follow 3-A Sanitary Standards and review your part’s design, your materials, and the additive manufacturing process itself. To help you get started, follow these best practices when it comes to designing 3D printed food-safe products:

Eliminate crevices and voids

Make sure that any section of your part or product that can come into contact with food (product contact surfaces) is free of crevices and voids. These features are difficult to clean and can allow bacteria to thrive. If your part requires voids or crevices, ensure that those areas can be easily accessed for cleaning when your product is disassembled.

Round any sharp corners

Sharp corners are difficult to clean, and like crevices and voids, can potentially harbor bacteria. With this in mind, you should round any corners within your design, and instead incorporate fillets with large radii when possible.

Ensure toughness

When you’re manufacturing food-safe products, make sure that your parts are robust enough for their applications. If they crack, corrode, or break down, bacteria can grow, putting users at risk. Additionally, if a part breaks, small pieces may contaminate the food, posing a danger to consumers and often requiring a recall of the product.

Smooth surface finishes

A part’s surface finish can be problematic, as rough surfaces have small pockets that enable bacteria to grow. However, creating food-safe 3D printed products with smooth, non-porous surfaces can be challenging, as 3D printers build parts layer by layer, resulting in microscopic crevices. To achieve surface smoothness, you can use:

Mechanical finishing: Mechanical finishing techniques, such as sanding, bead blasting, and polishing, can help smooth a part’s surface while also improving clarity.
Vapor smoothing: Compatible with certain plastics, vapor smoothing involves exposing 3D printed plastic parts to vaporized solvent. Your part’s external features and edges will melt and re-seal, creating a smoother, glossier surface without voids or crevices.
Surface coatings: In situations where mechanical finishing isn’t a viable or cost-effective option, you might be able to use a food-safe coating, such as food-grade epoxy or polyurethane. Make sure your coating is compatible with any cleaning products and other chemicals your part will come into contact with to avoid pitting, delamination, and blistering.

The additive manufacturing process you choose also plays a role in the amount of post-processing you’ll need to do. Technologies like stereolithography (SLA), HP Multi Jet Fusion (MJF), and Carbon® Digital Light Synthesis (DLS) produce parts with smoother surface finishes than fused deposition modeling (FDM), and typically require less post-processing. However, regardless of technology, even if a part is printed with food-safe materials, it might not be considered food-safe if the printer isn’t itself deemed food-safe. Something as small as an FDM printer’s nozzle containing lubricant can cause the resulting parts to be considered non-food-safe, so every detail counts.

How is additive manufacturing used in the food industry?

Additive manufacturing, unlike injection molding, doesn’t involve machining expensive tooling to mold plastic parts. By eliminating the cost and lead time associated with machining injection mold tooling, companies can save a great deal of time and money when making parts and maintenance tools for their factories, such as spacers, grippers, and assembly tools. Additionally, additive manufacturing — particularly when combined with digital part storage and factories with cloud-based manufacturing capabilities — is an ideal process for producing spare parts, keeping equipment up and running and avoiding expensive, unplanned downtime.

What materials are used in food-safe additive manufacturing?

When creating products that will come into contact with food, choosing the right material is essential. You’ll want to choose a non-toxic, non-contaminating, corrosion-resistant base material, and you’ll need to make sure any added coatings or dyes are also food safe.

Specific food-grade plastics that are compatible with the additive manufacturing process include:

Polyetheretherketone (PEEK): PEEK has high resistance to heat and dimensional stability, so it can be used in the microwave and dishwasher. It’s lightweight yet strong and can be manufactured with colorants, giving it plenty of design flexibility. PEEK can be found in coffee machine nozzles, mixing scrapers, blenders, kneaders, food packaging, and more.
ULTEM 1010: ULTEM 1010 is a strong, high-performance thermoplastic compatible with the FDM 3D printing process. In addition to being mechanically suitable for many applications, it has been certified to NSF 51, meeting the FDA’s minimum public health and sanitation requirements for materials used in the construction of commercial food equipment.

What are some sterilizable additive materials that meet food safety standards?

Manufacturers often use sterilizable additive materials, as the last thing they want is for bacteria to grow unchecked within a product that comes into contact with food. However, it’s important to know that not all sterilizable materials are necessarily food-safe materials.

Click here to download the sterilizable 3D printing materials chart.

Creating food-safe products with Fast Radius

The introduction of additive manufacturing to the food industry has changed the game. Thanks to 3D printing, companies can create food-safe products from a wide variety of materials quickly, cost-effectively, and on demand. However, creating food-safe products via additive manufacturing isn’t as simple as selecting appropriate materials. You’ll also need to pay attention to your printer, your part’s design, and your part’s surface finish.

There’s a lot to remember when trying to meet regulations and create food-safe products, so using an experienced manufacturing partner can put your mind at ease and ensure your customers aren’t put at risk by unsafe products. When you work with Fast Radius, our engineering team can help you choose an FDA-approved plastic that will meet your needs and ensure your design is ready for printing. You can also upload your part files to get an instant DFM analysis of your design, explore material options, and order your parts online — even using a purchase order (PO). Simply create an account to get started today or contact us to discuss the requirements for your next food-safe additive manufacturing project.

Visit our resource center to learn more about additive manufacturing, including what you can expect during the additive manufacturing process, the cost of 3D printing, and more.

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Complete guide to CNC Swiss machining

Tyler Vinyard — Wed, 05 Oct 2022 16:00:00 +0000

In 2021, the global Computer Numerical Control (CNC) machine market size was $56.40 billion. Given how fast, precise, and automated this manufacturing technology is, it’s hardly surprising that the global machine market is expected to grow in the coming years. As the demand for CNC machining grows, the demand for Swiss machining, a manufacturing process that falls under the overall umbrella of CNC machining, will also rise.

As with traditional CNC machining, Swiss machining is used with metal and plastic, offers fast production times, and can produce complex parts with tight tolerances. It’s an incredibly efficient, precise, and repeatable manufacturing process, though it differs in several ways from traditional CNC machining.

In this guide to CNC Swiss machining, we’ll go over what you need to know to decide whether Swiss machining is best for your project.

What is Swiss machining?

Originally developed to produce intricate watch parts for the Swiss watchmaking industry in the late 19th century, Swiss screw machines required a skilled operator who could turn handles and push levers to form the desired part. However, thanks to today’s CNC technology, Swiss machining is highly automated and can repeatedly produce complex geometries at tight tolerances with extremely fast cycle times.

As a subset of turning machines, also known as lathes, Swiss machines have stationary tools and a workpiece that can turn and move along the Z-axis, allowing for the creation of round and cylindrical parts. However, its sliding headstock and guide bushing set Swiss machines apart from other turning machines. The sliding headstock feeds the bar stock through a guide bushing, which supports and stabilizes the bar stock near the cutting point. This helps prevent workpiece distortion and enables the machine to accurately create different diameters, complex holes, hex edges, slots, and threads without the need for multiple setups or additional equipment.

When it comes to making parts, Swiss machining is the ideal production method for manufacturing high volumes of small components that require complex turning. Swiss machines are also better suited for machining long parts than traditional CNC turning machines, as they are less likely to cause deflections.

Key differences between traditional CNC turning and Swiss machining

The main difference between traditional CNC turning and Swiss machining is that Swiss machines have a moveable headstock that enables the workpiece to spin and move along the Z-axis, whereas the workpiece remains stationary when using conventional lathes.

Traditional CNC turning

Swiss machining; note the sliding headstock

Additionally, traditional CNC lathes generally have two, three, or four axes, but Swiss machines often have five, seven, or more axes, enabling operators to quickly machine even the most complex parts. Instead of performing multiple operations or using several setups on numerous machines, manufacturers can often do the job with one Swiss machine and fewer setups. It’s also worth noting that many Swiss machines can perform several tooling operations simultaneously, whereas traditional lathes usually complete one operation before moving on to the next, which can help further accelerate production.

By using a Swiss machine, companies can enjoy a reduction of secondary operations and tool changes, reduced labor costs, and faster turnaround times, all without sacrificing part quality. Since the bar stock is firmly supported, tolerances are tight and complex parts with thin walls or delicate features can be repeatedly manufactured.

Industry applications for Swiss machining

Swiss machining was initially used to create the tiny, intricate parts used in watches, and it’s still used to create long, small, or slender turned components across various industries. Its speed, accuracy, and relatively low costs have kept Swiss machining popular.

For example, Swiss machining’s high level of accuracy makes it an ideal manufacturing technology for the defense sector, where small, complex geometries with tight tolerances are often required for military hardware.

Swiss machining also has plenty of applications in the medical industry, where manufacturers can use Swiss machines to produce everything from electrodes to anchors to surgical tools.

In the aerospace industry, Swiss machining can produce components that meet the extreme precision required by the industry’s rigorous demands. The technology can be used to create everything from mechanical components for spacecraft motors to the cockpit controls’ electrical components.

Similarly, Swiss machining’s ability to produce quality and precise parts makes it a popular manufacturing process in the automotive industry. Here, companies use Swiss machines to fabricate bushings, pins, brake system and suspension components, and more.

Essentially, Swiss machining is an excellent production method for manufacturers who need to quickly produce a high volume of small, accurate parts with complex geometries and high-quality finishes for a relatively low cost.

Design tips for CNC Swiss machining

While CNC Swiss machining differs from traditional CNC machining, many best practices should still be kept in mind when designing your part to reduce machining time and costs as much as possible. For example, make sure you remember to:

Ensure your drawings are accurate and clear: You need to have legible and precise drawings to ensure your operator can quickly and correctly understand and machine your part. Include dimensions, tolerances, and material and finish information.
Use standard-sized holes: Incredibly small or deep holes can make machining more difficult and expensive, so it’s best to use standard-sized holes whenever possible.
Avoid sharp corners: Whether you’re using a traditional CNC lathe or a Swiss machine, your drill bits will be round, which means it will be incredibly difficult to produce sharp inner corners. While you can achieve sharp inner corners using methods like electrical discharge machining, this can be expensive and time-consuming. Thus, it’s best to always design your parts with rounded corners, as the drill bit will automatically leave an inside corner radius. To avoid chatter and premature tool wear, make sure your corner radius is slightly larger than the common trade sizes of tool diameters, such as 3 mm or ⅛ inch, for example.
Only include the necessary tolerance: Including unnecessarily tight tolerances can drive up machining time and overall part costs, so it’s best to only assign strict tolerances to areas where they truly matter.
Pay attention to wall thickness: While it’s possible to machine thinner walls with Swiss machines, it’s still best to avoid designing your parts with thin walls, as they can cause chatter, resulting in less-accurate parts with reduced surface quality. When it comes to plastic parts, thin walls can also result in warping and softening.

CNC Swiss machining with Fast Radius

Swiss machining is a fast, accurate, and cost-effective manufacturing method that’s ideal for creating large quantities of small parts that require complex CNC turning. However, as with any CNC process, it’s best to keep the above tips in mind when designing your parts to ensure your machining time and costs are as low as possible.

Whether Swiss machining is the ideal manufacturing process for your parts or traditional CNC turning is better-suited for your needs, working with an experienced manufacturing partner like Fast Radius can help you make the right decisions to get better quality parts faster. Start making the precision-machined parts you need today — contact us to get started or simply upload your part files to get an instant DFM analysis of your designs, explore material options, and to get a quote online.

Visit our resource center to learn more about designing for CNC machining, CNC tooling, material selection for CNC machining, and more.

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Know your materials: Polycarbonate (PC)

Alexa Rodriguez — Wed, 28 Sep 2022 16:00:00 +0000

Since its development in the mid-20th century, polycarbonate (PC) has been an increasingly popular material in manufacturing. Today, around 2.7 million tons of polycarbonates are produced each year globally. Over the years, various companies have created different formulas for polycarbonate, so there are several industry grades of polycarbonate to choose from. Some forms have more glass fiber reinforcement, while others have additives like ultraviolet stabilizers for protection against long-term sun exposure.

Strong and versatile, this amorphous thermoplastic is resistant to heat, impact, and many chemicals. As such, polycarbonate is ideal for components that need to be tough or repeatedly sterilized and is often used in the automotive and medical industries.

How polycarbonate is manufactured

Each company manufactures polycarbonates slightly differently, but polycarbonate materials have traditionally been created via the condensation polymerization of bisphenol A and carbonyl chloride. However, many companies have started to use diphenyl carbonate instead because carbonyl chloride is extremely toxic.

Regardless of whether carbonyl chloride or diphenyl carbonate is used, a bisphenol A solution in sodium hydroxide is required and then mixed with the carbonyl chloride or diphenyl carbonate solution in an organic solvent so polymerization can take place. When the polycarbonate forms, it will initially be in a liquid state. The solution will be evaporated to form granules, or ethanol will need to be introduced to precipitate the solid polymer.

Once created, polycarbonate is often sold in rods, cylinders, or sheets and can be used in various manufacturing processes. Polycarbonate is compatible with thermoforming, extrusion, and blow molding, but it’s most often used with injection molding. After all, as a thermoplastic, polycarbonate can be melted, cooled, and reheated without burning or significant degradation, making it an ideal injection molding material.

During injection molding, polycarbonate needs to be processed at a high temperature and injected into the mold with high pressure because polycarbonate is quite viscous. The melt temperature should be between 280°C and 320°C, and the mold temperature should fall between 80°C and 100°C. However, those numbers can vary depending on the grade of polycarbonate being used. For example, a high-heat polycarbonate will require a melt temperature between 310°C and 340°C and a mold temperature between 100°C and 150°C, whereas a PC-ABS (polycarbonate/acrylonitrile butadiene styrene) blend’s melt temperature only needs to be between 240°C and 280°C and its mold temperature can fall as low as 70°C and up to 100°C.

Properties and mechanical specifications of polycarbonate material

While there are several grades of polycarbonates, each with their own molecular mass, structure, and properties, all polycarbonates have a few things in common.

For one, they are known for their toughness and high impact resistance. As a result, polycarbonate is often used for applications that require reliability and high performance.

Despite their toughness and strength, polycarbonates are light weight, allowing for extensive design possibilities and relatively easy installation when compared to other materials.

Polycarbonates are also very resistant to heat and flames. A polycarbonate can maintain its toughness in temperatures up to 140°C, which means polycarbonate parts can withstand repeated sterilization. Polycarbonates also have light transmittance rates above 90% and good chemical resistance against diluted acids, oils, greases, aliphatic hydrocarbons, and alcohols.

A polycarbonate’s properties depend on its molecular mass and structure, so each material is slightly different. To give you an idea of what you can expect, here are some typical key characteristics and specifications:

Specific gravity: 1.21
Melt temperature: 295 – 315°C
Mold temperature: 70 – 95°C
Heat deflection temperature: 137°C at 0.45 MPa
Tensile strength: 61 MPa
Flexural strength: 90 MPa
Shrink rate: 0.5 – 0.7%
Rockwell hardness: 118R

As you can see, polycarbonate manufacturing has plenty to offer. However, there are a few things you’ll want to be aware of before selecting this material for a project. For example, its mechanical properties can degrade after prolonged exposure to water over 60°C. Polycarbonate is also susceptible to scratching, more costly to manufacture than many other materials, and vulnerable to diluted alkalis and aromatic and halogenated hydrocarbons. Additionally, the polycarbonate formulations without UV stabilizers can sometimes yellow over time when exposed to UV rays.

Common uses of polycarbonates in everyday life

Polycarbonate’s toughness and high impact resistance make it a popular material choice for automotive industry manufacturers, particularly when it comes to parts that must be clear or translucent and are subject to frequent impact, such as headlight and turn signal lenses.

In the medical industry, polycarbonate can be found in everything from incubators to dialysis machine housings. After all, polycarbonate is tough, resistant to heat, dimensionally stable, and able to withstand sterilization via FDA-approved methods including autoclaves and irradiation. Polycarbonate can be used in blood filters, reservoirs, and oxygenators, as well as surgical instruments. Plus, given its transparency, polycarbonate enables doctors to more easily monitor blood and track the administration of fluids.

Polycarbonate is also a material of choice in many household appliances, such as mixers, hair dryers, refrigerators, and electric razors. Other common uses for polycarbonate include exterior lighting fixtures, machinery guards, protective gear, bullet-proof glass, fuse boxes, television housings, roofing, skylights, greenhouses, suitcases, eyeglasses, and beverage containers, such as baby bottles, sippy cups, and refillable water bottles.

Getting started with polycarbonate

Polycarbonate is a strong and impact-resistant thermoplastic that’s used across a variety of industries. However, there are several different kinds of polycarbonate on the market, each with its own characteristics. Working with an experienced manufacturing partner like Fast Radius can make all the difference for product teams who are unfamiliar with polycarbonate or are looking to manufacture parts and products with materials that may be more suitable for a specific application. Want to see if polycarbonate is the right material for your next project? Create an account and upload your part files or contact us today to get started.

Want to learn more about other plastics so you can compare them to polycarbonate? Check out our resource center to learn about polycarbonate/acrylonitrile butadiene styrene (PC-ABS), polyethylene terephthalate (PET), polyetheretherketone (PEEK), and more.

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The post Know your materials: Polycarbonate (PC) appeared first on Fast Radius.

Examining the UV resistance qualities of polypropylene and nylon

Zak Marinko — Wed, 21 Sep 2022 16:00:00 +0000

There are countless thermoplastics on the market today, from acrylic to polyetherimide. Polypropylene and nylon are two other thermoplastics commonly used in manufacturing, so it’s important to understand the qualities of each before you consider these materials for your next project.

Polypropylene is a capable, low-cost crystalline thermoplastic often used in medical equipment, food containers, packaging, and water pipes. It’s most commonly used with the injection molding or CNC machining manufacturing processes, but it’s also possible to 3D print polypropylene. However, before you decide to 3D print your parts using polypropylene, it’s important to note that it does tend to warp more easily than many other 3D printing materials, and there may be more suitable options depending on what you’re making.

Likewise, nylon is also compatible with 3D printing, injection molding, and CNC machining, and is used across industries to manufacture everything from rope to engine components. It can be shaped into several different forms, including sheets, fibers, filaments, and films, and is often used in place of low-strength metals.

As you can see, nylon and polypropylene are versatile plastics with multiple benefits. However, designing parts for outdoor use requires selecting the right UV-resistant or UV-stabilized plastic, so it’s important to consider each material’s UV qualities to ensure your end product can withstand prolonged exposure to sunlight without breaking down. In this article, we’ll go over the UV resistance qualities of nylon and polypropylene to help you make an informed material choice.

What is UV-resistant plastic?

If your part will spend a significant amount of time outside or otherwise be exposed to sustained levels of UV radiation, you may want to use a plastic resistant to UV rays. For example, you may have seen some stadium seats, automotive parts, and lawn chairs suffer from discoloration, a loss of visual clarity, and/or a reduction in mechanical strength and impact resistance; this is because they were made out of a plastic with low UV resistance. Exposure to UV light can also make plastic parts more brittle and susceptible to breakage, cracking, deformation, or disintegration.

While almost no material is entirely resistant to UV light, some can absorb UV radiation. Adding stabilizers or additives can improve UV resistance for plastics that can’t absorb UV light. These non-UV-resistant materials produce free radicals (atoms with an unpaired electron), which can break down intermolecular bonds, negatively impact mechanical properties, and cause plastics to wear down.

Polypropylene UV resistance qualities in manufacturing

Polypropylene is an extremely tough yet flexible and lightweight material. It is resistant to mold, bacteria, water, oil, rot, electricity, and chemicals. However, polypropylene isn’t the best option for products that live outside or are regularly exposed to sunlight because it’s deeply affected by exposure to UV radiation. Specifically, it’s susceptible to UV wavelengths of 290 – 300 nanometers, 330 nanometers, and 370 nanometers. Exposure to high-intensity UV radiation for as few as six days can cause polypropylene to lose up to 70% of its mechanical strength, resulting in very brittle parts.

Polypropylene products will generally break down after a few months of direct exposure to sunlight, as the radiation will excite photons and create free radicals. However, using additives and coatings can help protect polypropylene parts from sunlight. For example, zinc oxide or titanium oxide fibers can block and absorb UV light, reducing the polypropylene’s exposure to UV radiation and extending the part’s life. Similarly, designing a polypropylene part with protective seals can help it better withstand sunlight, though getting polypropylene to bond with other materials can be difficult as it has little to no absorption tendencies and is quite slippery.

Even with additives, polypropylene will degrade quickly compared to naturally UV-resistant plastics like acrylic or high-density polyethylene (HDPE). Thus, we recommend against its use for products that will receive extended exposure to direct sunlight.

Nylon UV resistance qualities in manufacturing

Similarly, nylon is susceptible to degradation when exposed to UV radiation for prolonged periods, as UV light creates free radicals that impact nylon’s properties. When exposed to sunlight for a prolonged period, nylon parts will weaken and fade in color. Nylon is sensitive to UV wavelengths of 290 – 315 nanometers.

However, there are several nylon variations which offer varying degrees of UV resistance. For example, nylon 6/6 is less resistant to UV rays than nylon 6 or nylon 12. Thus, it’s important to consider each nylon variation’s mechanical strength, temperature resistance, abrasion resistance, and water resistance in addition to your product’s intended application when deciding which type of nylon to use for your project.

Choosing between polypropylene and nylon

Neither nylon nor polypropylene is particularly resistant to UV light, but polypropylene will likely degrade faster upon consistent exposure to UV radiation. However, you can boost both polypropylene UV resistance and nylon UV resistance with:

Stabilizers: When free radicals form, these additives trap them, preventing them from degrading the intermolecular bonds within the nylon or polypropylene. Hindered amine light stabilizers (HALS) are the most common type of stabilizers.
Blockers: Blockers work by preventing UV rays from reaching the polypropylene or nylon in the first place. Carbon black is a common, highly effective blocker for outdoor applications, but titanium dioxide pigment can also help increase your product’s longevity.
Absorbers: On the other hand, absorbers can absorb UV radiation and convert it into heat or other less harmful wavelengths. The most common absorbers are benzophenones and benzotriazoles, but other options exist.

It’s also worth noting that UV resistance isn’t the only factor to consider when choosing between polypropylene and nylon.

Polypropylene is stronger and more resistant to moisture than nylon, and its low melt viscosity makes it ideal for use in injection molding. Polypropylene is also resistant to electricity, oils, and bacteria, though it’s highly flammable and susceptible to chlorinated solvents and oxidation.

On the other hand, nylon has a higher melt viscosity than polypropylene. It also has good electrical resistance and is ideal for high-friction applications, as it can maintain its shape without much maintenance or lubrication. Nylon is also more malleable than polypropylene, which enables designers to create more complex shapes.

Producing polypropylene and nylon parts with Fast Radius

Polypropylene and nylon are acceptable materials for parts that will receive intermittent UV exposure. However, fluoropolymers (such as polytetrafluoroethylene, polyvinylidene fluoride, and fluorinated ethylene propylene), imides (like polyimide and polyetherimide), acrylic, high-density polyethylene, or polycarbonate may be better suited for parts that will receive prolonged UV exposure. If polypropylene or nylon is otherwise the best material for your needs, adding blockers, stabilizers, or absorbers can boost your product’s UV resistance and increase its lifespan.

When you work with Fast Radius, our team of experienced engineers can help you select the right material for your project. We’ll work with you from the design stage through production to ensure that your parts come out as intended. Additionally, by creating an account and uploading your part files using our cloud-based software, you can access instant DFM analysis of your designs and compare material options and manufacturing methods to ensure your part production is as cost- and time-efficient as possible. If you need help getting started, simply contact us to discuss our capabilities and what Fast Radius can do for you.

Visit our resource center to learn about choosing the right material for your CNC machining project, 3D printing with nylon, and more.

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The post Examining the UV resistance qualities of polypropylene and nylon appeared first on Fast Radius.

Additive post-processing: Bead blasting, vapor smoothing, and sanding

Pablo Simons — Wed, 14 Sep 2022 16:00:00 +0000

Additive manufacturing involves more than just sending your design off to the printer. Because 3D-printed parts often have visible layer lines or rough surfaces, post-processing can be used to ensure your parts look and feel finished — especially if you’re creating an end-use product.

In addition to cleaning, fixing, curing, and coloring, smoothing and sanding are two popular additive post-processing options. Both can result in pieces that look and feel smoother, but they aren’t interchangeable. Each process is different and better suited for different situations.

Benefits and drawbacks of post-processing smoothing

Post-processing smoothing is ideal for cases where aesthetic appearance is a top priority, but it can also improve your part’s mechanical performance when creating a watertight part.

After cleaning off your part to remove any excess resin, you may need to smooth it to achieve your desired surface finish. There are several different smoothing processes that can be used, depending on the process and material you selected, as well as your desired surface finish. Two of the most common smoothing options that achieve the best results are bead blasting and vapor smoothing.

Bead blasting

Bead blasting involves blasting glass or quartz beads at the surface of a part at high pressure. Propelling the beads at a surface cleans and polishes the surface to the desired finish. Fine glass beads leave a “dull” or “satin” smooth finish that’s a cross between a matte and high-gloss finish. Coarse glass beads yield uniform roughness and mask any imperfections.

The left side of this jig shows how bead blasting can even out a part’s surface. The right side of the part has not undergone post-processing. Manufacturing process: Carbon® Digital Light Synthesis

The left side of this part has been sanded with 120 grit sandpaper. The right side shows how bead blasting smooths a part’s surface after sanding. Manufacturing process: Carbon® Digital Light Synthesis

Vapor smoothing

Vapor smoothing, also known as chemical smoothing or chemical vapor smoothing, involves exposing your part to a vaporized solvent that reacts with the part’s outer layer. The vapor will liquefy and redistribute material on your part’s surface, melting away layer lines and sealing small cavities to create a smooth and glossy surface.

Left: An unprocessed sample of PA 12 Right: A vapor-smoothed sample of PA 12 Manufacturing process: HP Multi Jet Fusion

Unfortunately, it’s impossible to control post-processing smoothing completely. It’s all too easy to melt or blast away small features when smoothing your part or to accidentally remove material unevenly, impacting your part’s dimensional accuracy. This means smoothing processes require close observation to achieve an optimal finish while reducing the risk of damage to small features.

Benefits and drawbacks of post-processing sanding

Sanding is a post-processing option that removes more material than smoothing. Rough surface finishes are normal in areas where supports are used during the 3D printing process, and prominent layer lines are also relatively common when using fused deposition modeling (FDM). If you have nubs left behind from support structures and need a part that looks and feels smooth, sanding may be the right option to achieve your desired finish.

Much like smoothing, there’s a tradeoff between achieving a smoother surface and an accurate part, and sanding can sometimes remove material unevenly. This can impact your part’s dimensional accuracy.

Manual post-process sanding is also a labor-intensive and time-consuming process. Parts need to first be sanded with low-grit sandpaper, such as 120 grit, before re-sanding with higher grit sandpaper, such as 240 grit, 800 grit, and even 2,000 grit to achieve a desirable finish. Leaving this step to the professionals may cost more money than attempting to sand parts yourself, but experts with the right tools and skillsets will reduce the risks of damage to your parts and will save you time, as well.

Left to right: Unprocessed, 120 grit sanding, 240 grit sanding, 800 grit buffing/sanding (finished part) Manufacturing process: Carbon® Digital Light Synthesis

Why choose post-processing in additive manufacturing?

Both smoothing and sanding take time, effort, and expertise to achieve quality results and can also be a costly endeavor, especially when done by hand.

While unfinished parts may be acceptable for prototyping and are cheaper and faster to produce, they aren’t usually suitable for end-use products. By engaging in smoothing, sanding, cleaning, curing, fixing, and coloring, you can refine your 3D printed parts, making them stronger (in the case of vapor smoothing FDM parts), smoother, more aesthetically pleasing, and even more functional.

Post-processing parts with Fast Radius

Post-processing smoothing and sanding can significantly improve the look and feel of your part. However, each process has its drawbacks and the potential to create inconsistencies. To ensure your final part or product is as intended, consider partnering with an experienced manufacturer.

If you work with Fast Radius, our team will partner with you to refine your design, print your product, and post-process it when necessary. You can also upload your part files to access design insights, view cost analyses, and get a quote instantly. Create an account today to get started and to begin leveraging the benefits of cloud manufacturing.

Want to learn more about additive manufacturing? Check out our resource center to learn about layer height, support structures, and more.

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The post Additive post-processing: Bead blasting, vapor smoothing, and sanding appeared first on Fast Radius.

Learning Center and Resources | Fast Radius

A guide to chemical finishes for CNC machined parts

Choosing your chemical finish

Anodizing

Passivation

Black oxide coating

Chem film

Electropolishing

Electroplating

Chrome plating

Polytetrafluoroethylene (Teflon) coating

Electroless nickel plating

Zinc plating

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