Tolerances in manufacturing are a defined range of measurements or physical traits that ensure a product is functional and looks aesthetically pleasing. These tolerances are typically the minimum and/or maximum range of measurements of the product in the X, Y, and Z axes. But, why are tolerances so important in precision fabrication? In this blog, we will explore the processes of precision plastic fabrication and why tolerances matter.

What is Precision Plastic Fabrication and CNC Machining?

Precision plastic fabrication is the process of designing and manufacturing plastic parts and products for demanding industries. Some common industries that rely heavily on precision fabrication processes include defense, medical, electronics, aerospace, oil and gas, and more.

Many times, precision plastic parts and products are manufactured through CNC machining. This manufacturing process is so precise that it can yield complex products and parts with a smaller chance of errors. CNC machining involves a pre-programmed computer software that dictates the movement of factory tools and machinery, creating complex, detailed parts with tight tolerances. There are a few different CNC processes that are commonly used to create parts with tight tolerances. 

  • CNC Milling: This process uses a cylindrical cutter on an axis to shape flat surfaces, grooves, and other characteristics.
  • CNC Turning: During this process, the workpiece is spun at a high speed around a stationary tool which shaves material away to form the desired product.
  • CNC Grinding: A rotating grinding wheel removes material from the workpiece to achieve a high degree of surface quality on your products.
  • CNC Lapping: An abrasive material and workpiece are rotated at high speeds and brought into contact with each other to yield a smooth surface finish.

There are also other precision plastic fabrication services that are utilized by many industries to further improve their products. These services include:

  • Plastic Annealing: This process heats plastic to half of its melting temperature and then is allowed to cool. This gives the plastic the ability to relax, preventing warpage during production.
  • Plastic Bending: This is used to help shape the plastics to find the needs of their applications.
  • Plastic Bonding: This process is used to bond plastics to other plastics or other substrates. There are three options — solvent bonding, ultrasonic bonding, and adhesive bonding.

Why Are Tolerances Important?

Improved Function

Tolerances ensure that your products will fit their exact application. This includes fitting properly into tight spaces or functioning properly in the given space allotted. This gives your products the ability to function properly without having to worry about wear or damage to your overall application or the individual parts.

Improved Look

Applying tolerances to your product allows you to control the dimensions of your parts. This gives you the ability to make sure everything sits flush with each other and fits properly together, improving the overall look of your products.

Account for Error

In manufacturing, tolerances assume a certain amount of error. This gives your manufacturer the ability to machine your products within this error amount, making it less likely for you to have to remake products down the line, thus saving you time and money.

Cost-Effective Manufacturing

Since the product is as precise as it needs to be, you will only be paying for the materials, tools, and labor you use. This cuts back on unnecessary manufacturing processes, wasted material, and other costly extras you don’t need.

Faster Time to Market

When you determine tolerances up-front, you will save time and money in the long run. Not only will you know exactly what processes you need to use, saving you time on production, but you also won’t have to worry about mismeasurements and inconsistencies that can delay your products hitting the shelves.

Reduce Manufacturing Complexity

By specifying exactly what you want and the required tolerances of your products, your manufacturer will know exactly what it will take to create your products. This allows your manufacturing process to run more smoothly and efficiently.

For Your Precision Plastic Fabrication Needs, Turn to Ensinger

At Ensinger, we have been manufacturing precision plastic parts for decades. Our team has worked with various critical industries, including medical, semiconductor, oil and gas, and more to create the parts they need for safe, efficient machinery and products.

We utilize CNC machining and other plastic fabrication services to ensure your products are exactly what you need. Our team has worked with tight tolerances and we have honed our skills and processes to ensure your needs are met every step of the way.

Contact our team today to learn more about what we can do for you.