Custom Polycarbonate Parts
In China, WeProFab is one of the custom polycarbonate parts supplier and fabricator. We can do different processes for any products we fabricate. We sustained the fabrications process through our advanced machines. We can also custom your ideal polycarbonate parts. Send us your drawing!
Get WeProFab Custom Polycarbonate Parts to Delight Your Customers
WeProFab custom polycarbonate parts are fabricated with high-class raw materials. We proudly offered it in great quality and supply based on the request. We are responsible to help you delight your customers.
WeProFab is able to perform different processes when customizing polycarbonate parts. We are the leading manufacturer that trusted worldwide.
There are many processes in fabrication we perform. We can do drilling processes and offer different fixed products at an affordable cost.
We can do injection molding for custom polycarbonate parts. If you look for a trusted and qualified manufacturer, WeProFab is perfect for your option.
If you are looking for a supplier who can meet your desired designs and customizations, WeProFab is responsible for it. We can laser cut custom polycarbonate parts.
WeProFab custom polycarbonate parts can be silkscreen machining. WeProFab has a complete device to make customize polycarbonate parts.
WeProFab is responsible to do the polishing for custom polycarbonate parts. We offered great durability of our custom polycarbonate parts that we supplied.
WeProFab is a joint-venture company between WeeTect Material Limited and a Chinese local fabrications manufacturer. Our main purpose is to provide one-stop solutions. We fabricated custom polycarbonate parts durably and affordable advantage for business purposes.
WeProFab custom polycarbonate parts are high-quality. Every business owner chooses custom polycarbonate parts since it is negotiable and generates excellent profits because of its abilities.
In fabricating custom polycarbonate parts, we follow standards such as RoHS, REACH, and UL. Through this, we ensure the fulfillment of every customer especially their demands.
We have the full capacity of custom polycarbonate parts like automotive parts, motor parts, and a lot more to provide. We can help you provide your custom polycarbonate parts that you desired.
Custom Polycarbonate Parts to Boost Your Business
Why WeProFab Custom Polycarbonate Parts
It is not easy to find custom polycarbonate parts for any applications. But always think that if you have a reliable and certified partner in the business, it will be easy for you to purchase.
In China, WeProFab is one of the reliable fabricators of custom polycarbonate parts. If you look for a great offer for your different orders for custom polycarbonate parts, WeProFab is great to consider.
In finding a trusted partner, you should be careful and be watchful who will be your choice. At WeProFab all that you desired are attainable and ready to ship.
Our custom polycarbonate parts are durable and perfect for the target applications and installations. Based on the request from our customers, our staff ensures to provide the right product. WeProFab avoided returns through our watchful team.
Custom Polycarbonate parts are made CNC machining and laser.
You can find a lot of suppliers and fabricators. But there are some offered quality and friendly offers. You must be watchful to save your budget. To run a business, WeProFab is great to consider as your supplier since we guide and handle the whole of the process.
In China, purchasing products for business is a successful tactic. All the possible processes are extremely complex. But expect WeProFab as your great partner.
WeProFab will ensure efficient and smooth operation and let your business grow as you want. WeProFab’s first priority is to ensure one-stop solutions for every customer.
Our custom polycarbonate parts are profitable and negotiable that passed standards. We are able to CNC, laser-cut, drilling, injection molding, and a lot more processes.
If you need to deal with us today, WeProFab can help you all the way. Send your instant quotes and your ideal custom polycarbonate parts. Contact us directly today and let us help you expand your business!
How To Custom Polycarbonate Parts
Polycarbonates are amorphous thermoplastic whose chemical structure is composed of carbonate groups.
Custom polycarbonate parts are parts made from polycarbonate materials.
They are tough, strong, durable, easy to work on, moulded into different structures and at times optically transparent.
- Step 1: Design Custom Polycarbonate Parts You Need
- Step 2: Choose Suitable Material For Custom Polycarbonate Parts
- Step 3: Machining And Fabrication Of Custom Polycarbonate Parts
- Step 4: Finishing Procedures For Custom Polycarbonate Parts
- Quality Inspection Of Custom Polycarbonate Parts
- Light Transmission Test
- Benefits Of Custom Polycarbonate Parts
- Limitations Of Custom Polycarbonate Parts
Step 1: Design Custom Polycarbonate Parts You Need
Custom polycarbonate part
Design engineers must factor functional requirements of the parts, ergonomics, aesthetics as well as economics in the design of polycarbonates.
Other factors like design stages involved such as evaluating process options, conducting prototype tests, simulation, reduction of production cost among others.
You will evaluate the parts to make and the materials required.
You must also consider the mechanical loading, the processing technology to be used, the colour of the parts, and the surface finish.
You can use CAE to simulate, validate and optimize the design and processing of the polycarbonate product.
The design process involves; initial design, material selection, planning for manufacture, planning for the structural need for the assembly, and anticipation of mould related consideration.
Polycarbonate parts include; connectors, housings and covers, boxes, insulators, gaskets, lenses, seals, optical storage media, safety helmets etc.
Step 2: Choose Suitable Material For Custom Polycarbonate Parts
virgin polycarbonate materials
Custom polycarbonates are made using different materials.
They can be polycarbonate pellets or polycarbonate sheets.
They are two types of polycarbonates; virgin polycarbonates and recycled polycarbonates.
Virgin polycarbonates are new raw polycarbonate materials that have not been used before.
The benefits of using virgin polycarbonate material include;
- They are incredibly strong, lightweight and fire-safe.
- They have high impact strength.
- Heat resistant.
- Outstanding weather resistance.
- Recyclable and safe.
- Great electric insulation.
- Conforms to food standards.
Recycled polycarbonate materials are those obtained from recycling other polycarbonate parts.
They have high temperature and chemical resistance making them applicable in many areas such as vacuum forming.
Polycarbonates are classified into different grades.
They are normally classified as standard, flame retardant, hard-coated or anti-static grades.
The choice of polycarbonate to use is largely dependent on where the polycarbonate material is going to be used.
Their grades exist due to the wide range of essential features that polycarbonates have.
Standard Polycarbonates Grade
These are ordinary polycarbonate materials that have not been a further process to improve their properties.
They are available in a wide thickness and texture range that are very useful in graphic art applications.
The key features of this grade are;
- Superior UV ink adhesion and accuracy thus suitable for screen printing.
- High dimensional stability
- Can be thermoformed easily.
- Good thermal insulation and rated UL94.
- High resistance to temperature fluctuation, impact and chemicals.
Flame Retardant Polycarbonate Grade
They are used in electromagnetic wave shields and electrical insulation.
Besides, they have a flammability standard of UL94
Hard-coated Polycarbonate Grade
These polycarbonates are abrasion and impact resistant.
They are mostly used in automobile interiors and electrical components.
Anti-static Polycarbonate grade
They control electrostatic discharges.
Besides, they are coated to achieve resistivity.
They are used in the electronics industry.
Step 3: Machining And Fabrication Of Custom Polycarbonate Parts
Cutting To Form Custom Polycarbonate Parts
Cutting polycarbonates depends on the process used;
To cut using sawing polycarbonate method, you need the following tools;
Sawing machine: either circular or band saws
Safety gear such as goggles and gloves
Marking and measuring tools
Though polycarbonate sawing is cost-effective, various problems are likely to arise during the process.
Melted Or Gummed Edges Of The Polycarbonate.
This can be solved by:
Reducing the number of polycarbonates being sawed.
Checking the temperatures of the cutting blade and cooling it whenever it is hot.
Adjusting the cutting speed of the saw and the feed rate of the polycarbonate part.
Use a lubricant that is recommended by the manufactures.
Make sure the blade is sharp enough.
Check the alignment of polycarbonates and align accordingly where necessary.
Chipping Of The Polycarbonate
This can be reduced by;
- Reducing the feed rate of the polycarbonate and the tooth size of the blade.
- Sharpening the blade
- Ensure that the blat is firmly in place.
- Ensure that the polycarbonate is properly clamped.
This is the most used technology and uses laser light to cut polycarbonates.
It has various advantages, such as;
- Precise and flexible cutting of parts.
- No flaking of the polycarbonate parts
- No need to clean the tool after use
- No direct contact of the tool with polycarbonate hence there is virtually no wear and tear.
It is worth noting that cutting polycarbonate parts has a lot of friction which causes heat to build up.
for this reason, always cool the polycarbonate part using either air or water.
Polycarbonate parts will begin to soften when the temperatures exceed 130°C.
Bending To Make Custom Polycarbonate Parts
There are different techniques used in bending of polycarbonate;
Bending polycarbonate sheet
Cold Line Bending
This is the bending of polycarbonates without heating.
You must consider several factors during this process such as the polycarbonate thickness, angle of bending and the tooling.
It is therefore recommended that you:
- Use tools with sharp edges
- Allow enough time after bending, around one or two days.
- Do not force the polycarbonate into the final form or reduce the angle of bending at the time of installation.
- Overbend the polycarbonate to counter the spring back after the effect of the polycarbonate.
- Attempting this procedure on a sample piece before committing to a larger piece.
Cut the polycarbonate to a pre-bending size after a successful sample piece test run.
Give a smooth finish to the edges of the polycarbonate to prevent cracking on the bend line.
Bend the polycarbonate rapidly with the protective finish still in place.
To counter the spring back effect, bend the polycarbonate 20° – 40° more than the desired bend angle.
The elastic limit for cold line bending is 90°.
Do not use this technique on polycarbonates that have UV or hard coating.
Bending on such polycarbonates weakens the efficacy of the additive along the bend line.
The procedure is limited to polycarbonates used in low impact situations.
This is the processing of bending the whole polycarbonate to form a dome.
The minimum radius of the dome to be attained by multiplying the polycarbonate’s thickness by 100.
The minimum radius varies with the variant of the polycarbonate used.
Harder variants have higher minimum radii.
Brake Bending Polycarbonates
This technique uses a press brake to change the polycarbonate into a desired final shape.
it utilizes the relative flexibility of polycarbonates in the processing of polycarbonates.
Brake bending occurs when the polycarbonate is held on a ram.
The mobile ran moves the polycarbonate to a stationary die to force the polycarbonate into the desired form.
There are three types of press brakes used in brake bending of polycarbonates;
- Manual press brake,
- CNC press brake, and
- Hydraulic press brake.
- Bending polycarbonates with a heat gun
- Forming bends by thermoforming polycarbonates
CNC Machining Custom Polycarbonate Parts
CNC machining polycarbonate
Polycarbonates have high machinability and great mechanical properties
The mechanical properties include; high toughness, hard hardness, great temperature resistance, impact strength.
These properties make it easier for CNC machining practices.
They are ideal for high accuracy, high precision and repeatability application such as electronics, medical, food, optical and automotive industries.
CNC machining process involves turning, milling, drilling among other techniques.
It is very easy to cut polycarbonate though very sharp tools and appropriate equipment should be used.
This will reduce vibration and ensure the safety of the user.
Injection Molding Custom Polycarbonate Parts
Figure 6 Custom injection molded polycarbonate part
Plastic injection molding is the most common method used in the fabrication of polycarbonate parts.
This mothed involves high temperatures to reduce the viscosity of the polycarbonate.
The bot melt polymer is pressed into a mould at very high pressures.
Upon cooling the mould, the molten polymer is given a designed shape and characteristics.
This process is mostly used in the manufacture of plates and bottles.
The wall thickness of the mould should not be too thin since polycarbonates have poor flowing capabilities.
Extruding Custom Polycarbonate Parts
Polycarbonate extrusion process
There are different types of extrusion, namely;
- Hot extrusion
- Cold extrusion
- Warm extrusion
- Friction extrusion
- Micro extrusion
Hot extrusion is done at recrystallization temperatures to prevent the material from hardening and allow easier pushing through the die.
Mot hot extrusion processes are done by hydraulic presses.
In polycarbonate extrusion, the polymer is melted and passed through a cavity to give it the desired shape.
Upon cooling, the melt attains and maintains the designed shape that has been acquired.
The extrusion process is mostly used in the manufacture of polycarbonate sheets, profiles and long pipes.
Cold extrusion is done at room temperatures and is advantageous in that;
- There is no oxidation of the material
- Products have higher strength due to cold working
- There is very close tolerance in the final product.
- Products have a better surface finish.
Some of the products of cold extrusion are collapsible tubes and fire extinguisher cases.
Drilling Custom Polycarbonate Parts
Drilling polycarbonates is the process of creating holes or circular cross-sections on a thermoplastic material using a drill bit.
Drilling of polycarbonates is applicable in the automotive industry, construction industry, pool enclosures, household appliance assembly, and display assembly.
Several reasons for drilling polycarbonates are:
- To allow for attachment of other parts on the surface.
- To create holes for screws on the polycarbonate.
- To reduce the overall cost of producing polycarbonates.
- To guarantee and enhance the safety of polycarbonates.
Drilling polycarbonates involves various steps;
- Evaluating the type of material used in the polycarbonate.
- Determining the techniques of drilling polycarbonates that you are going to use.
- Assembling all the tools and equipment required for the drilling process.
- Drilling of small pieces before you can drill larger surfaces.
- Place the polycarbonate on the surface and clamp both sheets.
- After switching on your drilling machine, start the process of drilling into the polycarbonate sheet gradually.
- During the drilling process, maintain the pace for consistency.
Key considerations that must be factored in are;
- Drilling speed
- Size and material of the drill bits
- The thickness of the polycarbonate material to be drilled.
- Size of the hole to be drilled into the polycarbonate.
- Type of the drilling machine to be used.
- Type of the drill bit to be used.
Thermoforming Custom Polycarbonate Parts
This is the process of heating polymers to high enough temperatures to enable easy bending or flexibility of the material in the mould.
The polycarbonate sheet is then stretched into a mould and cooled to produce the desired shape.
Thin-gauge thermoforming polycarbonate is mostly used in the manufacture of disposable cups, containers, lids, trays, among others for food and medical industries.
Thick-gauge thermoforming is used in vehicle doors and dash panels, refrigerator liners and plastic pallets.
Joining Or Bonding Custom Polycarbonate Parts
This is usually the last stage in the machining and fabrication of polycarbonate parts.
There are different ways of joining polycarbonate parts:
This technique uses fasteners to join various polycarbonate parts together.
Rivets or bolts and nuts are used in this process.
Bonding Polycarbonate Parts.
You use adhesives or bonding tapes to join polycarbonate surfaces.
The alternative used in joining the parts must be compatible with the polycarbonate parts.
Like the bonding technique, welding polycarbonate parts can be used for joining immobile parts.
This technique is strenuous and therefore less common in polycarbonate joining.
Step 4: Finishing Procedures For Custom Polycarbonate Parts
Finishing procedures help in improving the aesthetic value, performance and reliability of polycarbonate parts.
They are done through the methods explained below;
Coating Polycarbonate Parts
The coating is used to improve the performance of polycarbonate parts.
Polycarbonates are not fog-resistant or abrasion resistant, cannot eliminate glare or prevent graffiti.
To improve these shortcomings, you must choose an appropriate coating method.
Such methods include;
Antifog coating: this is a hydrophilic substrate that interacts with water droplets to eliminate fog on polycarbonate parts.
Anti-scratch coating: a coating made from silicon to prevent the possibility of formation of scratches on polycarbonate parts.
Photochromic coating: it combines anti-fog, hard, abrasion-resistant and other colour tinting coating.
Polarized technology: used to eliminate glare that brings about partial blindness.
It increases the depth of perception.
Anti-reflective coating: eliminates glare and excess light can cause partial blindness.
Has a thin dielectric that prevents reflection and glare.
Tinting technology: improves vision and are also stylish.
Hydrophobic coating: eliminates dust, moisture on surfaces.
This allows for a “self-cleaning” polycarbonate part.
UV protection coating: protect polycarbonate part from UV radiation.
Polishing Or Sanding Custom Polycarbonate Parts
You can either dry or wet sand polycarbonate parts.
A major disadvantage to this method is gumming of the polycarbonate parts.
You can get very smooth surface finishes when using wet sanding.
For the best finishes, use solvent polishing on polycarbonate parts.
The final product is glossy and has very smooth edges.
You can also add glacial acetic acid to prevent the formation of humidity blush.
Painting Polycarbonate Parts
Painting is used to improve the appearance of polycarbonate parts.
In this process, you simply apply paint to the parts.
You must consider the compatibility of the paint to the polycarbonate part.
Some paints might corrode or interfere with both the physical and chemical properties of polycarbonate parts.
Blending hard coats and flexible primer help in giving the parts a good finish.
Printing On Polycarbonate Parts
Polycarbonate part printing helps in personalizing the product.
The graphics printed can be both decorative and functional.
There are various options in polycarbonate parts printing;
- Digital printing on polycarbonate parts.
- Polycarbonate 3D printing
- Polycarbonate silk screen printing
You must consider compatibility when choosing any type of polycarbonate part printing.
Laminating Custom Polycarbonate Parts
You can use optical level lamination to improve the performance of polycarbonate parts such as glass.
Lamination of polycarbonate also allows for the production of bulletproof parts.
Hot Stamping Custom Polycarbonate Parts
It is mostly a decorative process.
Ink is transferred to a polycarbonate part at high temperatures.
Hot stamping is due normally’ at 375°F and 60 psi for about 2 to 3 seconds.
Quality Inspection Of Custom Polycarbonate Parts
Polycarbonates must conform to various standards such as; UL94 for flammability and ISO 9001: 2015.
Some of the tests you can use to check the quality of polycarbonates.
This is the first test you can do when buying polycarbonate parts.
This is done by checking the type of material used to make the polycarbonate parts.
Normally, you can use new raw materials or recycled materials to make polycarbonate parts.
Polycarbonate parts made from recycled material have a yellowish surface when viewed in direct sunlight.
Those produced from new materials are clear and have bright surfaces.
You cut a small piece of the polycarbonate and bend it several times.
Low-quality polycarbonates will break after 2 or 3 bends.
Higher quality polycarbonates parts can be bent up to 15 times.
You examine the thickness of the cross-section area of the polycarbonate alongside its weight.
You have to ensure that the thickness is uniform across the polycarbonate.
Its weight distribution should also be uniform.
Light Transmission Test
A good polycarbonate should transmit more than 75% of light.
Poor quality polycarbonates transmit less than 75% of light.
Benefits Of Custom Polycarbonate Parts
Some of the benefits of custom polycarbonate parts include:
Custom polycarbonate part
- High impact resistance which makes them virtually unbreakable
- Easy to machine, fabricate and manipulate into any desired shape for the product
- Easy to customize by adding coating technologies
- Resistant to most chemicals and can withstand wide temperature ranges
- Better optical transmission properties
- Can accommodate great dimensional stability and are resistant to most weather changes and patterns
- Are shock-resistant
- Have an excellent electrical insulation advantage
- Are rate UL94 i.e., fire and flame resistant
- Suitable for many applications such as making goggles and helmet visors.
- Absorb very little amounts of water
Limitations Of Custom Polycarbonate Parts
They are costly to produce since they require high temperatures and a better production system to prevent pollution.
Polycarbonate parts that lack anti UV treatment are prone to degradation.
Purchasing polycarbonate parts is very expensive.
For optimal performance, you must add other forms of treatment.
Polycarbonates offer unlimited performance possibilities and a wide range of applications.
For all your custom polycarbonate parts from China, contact WeProFab now.