CNC Machining PI (Polyimide)
- Superior Impact Resistance: Ideal for aerospace, medical, and industrial applications.
- Precision：0.01mm
- Fast Turnaround Times: Receive your parts in just 1-7 days
- Certified Quality: ISO9001:2015 and IATF16949 certified processes for top-quality results.
Table of Contents
Ensuring 0.01mm Precision in CNC Machining PI (Polyimide)
At Modo Rapid, we deliver high precision in our PI machining processes, achieving tolerances up to ±0.01mm. This precision is critical for applications that demand the highest level of accuracy, such as in aerospace and medical industries.
PI Material Selection
Which PI Grade is Best for My Application?
Choosing the right grade of PI is essential to ensure optimal performance and durability. PI (Polyimide) is known for its excellent thermal stability, chemical resistance, and mechanical properties, making it suitable for demanding applications.
What PI Grades Can I Choose?
- General-Purpose PI: Offers high strength and thermal stability, suitable for a wide range of applications.
- Thermal PI: Engineered for extreme temperature environments, ideal for aerospace components.
- Electrical Grade PI: Provides excellent electrical insulation, used in electronic components.
- Wear-Resistant PI: Enhanced with additives to improve wear resistance, perfect for industrial applications.
How Modo Rapid Ensures Your PI Parts Remain Deformation-Free
Machining PI requires specific expertise. At Modo Rapid, we ensure your PI parts maintain their integrity throughout the CNC machining process.
Heat Buildup
PI can deform if not machined correctly due to heat. We manage this by optimizing cutting parameters and using appropriate cooling techniques. Our high-pressure coolant systems help minimize heat, ensuring high-quality PI parts for you.
Tool Wear
PI’s hardness can lead to tool wear. We use specialized cutting tools and appropriate feed rates to ensure efficient machining and long tool life, delivering precise parts that meet your specifications.
Workholding
PI’s properties require secure workholding during CNC machining to prevent deformation. We ensure a tight grip and maintain constant tool motion, guaranteeing that your parts are machined to perfection.
What Are the Maximum Part Sizes and Complex Geometries You Can Handle?
- Part Sizes: We can machine parts with maximum dimensions of 1800mm x 800mm x 600mm, meeting the needs of most industrial applications.
- Complex Geometries: Our 5-axis and 3-axis CNC machining centers can precisely machine complex geometries, including internal channels, intricate surfaces, and high-precision apertures. Our equipment can manage fine features and tight tolerances, ensuring your design intentions are perfectly realized.
What Advanced CNC Equipment Do You Have for Machining PI?
- 5-Axis CNC Machining Centers: Capable of producing complex geometries and intricate designs, ensuring high accuracy and smooth finishes on HDPE components.
- High-Speed CNC Mills: Equipped with robust spindles and high feed rates, ideal for efficiently machining HDPE while maintaining tight tolerances.
- Multi-Tasking CNC Lathes: Combining milling and turning capabilities for versatile and efficient production of HDPE parts in a single setup.
- Precision CNC Grinders: Essential for achieving fine surface finishes and exact dimensions required for high-performance HDPE components.
- EDM (Electrical Discharge Machining): Utilized for cutting intricate shapes and hard-to-machine areas, providing high precision without inducing stress in the HDPE material.
PI Parts Finishes
Surface Finish Options
- Polishing: Achieves a smooth, glossy surface ideal for components where aesthetics and low friction are important.
- Bead Blasting: Creates a uniform matte finish that can reduce glare and improve the part’s surface quality.
- PVD Coating: Provides a durable and high-quality finish that can enhance the surface hardness and wear resistance of PI parts.
- Painting: Offers protection and aesthetic appeal, available in a range of colors and finishes.
Impact of Surface Preparation on PI Parts
Proper surface preparation is essential to ensuring the performance and durability of PI parts:
- Enhanced Durability: Proper surface preparation can increase the lifespan of PI parts by improving resistance to wear.
- Improved Functionality: A well-prepared surface can reduce friction and improve the efficiency of mechanical components.
- Aesthetic Appeal: High-quality finishes enhance the visual appeal of PI parts, making them suitable for both functional and decorative applications.
PI Part Surface Finish
Cost Calculation for Custom PI Parts
The cost of machining PI parts at Modo Rapid is determined by several key factors:
- Material Costs: PI is a premium material, and its price significantly influences the overall cost.
- Complexity of Design: Parts with intricate designs and tight tolerances require more time and specialized tools, increasing costs.
- Machining Time: Longer machining times due to PI’s hardness and the need for precise operations.
- Surface Finishes: Additional processes such as polishing, painting, or coating add to the total cost.
Example: Cost Calculation
- Dimensions: 100mm x 50mm x 10mm
- Complexity: Medium complexity geometry
- Surface Finish: Textured
- Quantity: 50 pieces
Material Cost
- Price of Polyimide (PI): $150/kg
- Weight per part: 0.12 kg
- Total material cost: 50 pieces x 0.12 kg x $150/kg = $900
Machining Cost
- Machining time for medium complexity parts: 0.4 hour/part
- Machining rate: $50/hour
- Total machining cost: 50 pieces x 0.4 hour/piece x $50/hour = $1,000
Surface Finish Cost
- Precision finishing cost: $5.00/piece
- Total surface finish cost: 50 pieces x $5.00/piece = $250
Tool and Equipment Wear
- Polyimide (PI) causes moderate tool wear, requiring regular tool replacement.
- Estimated tool and equipment wear cost: $150
Other Costs
- Quality control and inspection fees: $120
- Packaging and shipping fees: $60
Total cost = Material cost + Machining cost + Surface finish cost + Tool and equipment wear + Other costs
Total cost = $900 + $1,000 + $250 + $150 + $180 = $2,480
Cost per part = Total cost / Quantity
Cost per part = $2,480 / 50 pieces = $49.60/piece
This example provides a rough estimate of the cost for CNC machined PI parts. Actual costs will vary based on specific designs, process requirements, and quantities. To receive an accurate quote, please provide detailed mechanical drawings and technical specifications. We will then provide a customized quote based on your needs.
Production Lead Time and Delivery Time
Typical Lead Time from Order Placement to Delivery
At Modo Rapid, our standard lead time from order placement to delivery typically ranges from 1 to 2 weeks. This timeline includes:
- Order Confirmation and Planning: 1-2 days
- Procurement of Materials: 2-3 days
- Machining and Production: 5-7 days
- Quality Control and Inspection: 1-2 days
- Packaging and Shipping: 1-2 days
How Do We Deal With Your Expedited Orders?
Yes, we can shorten the production time for expedited orders. If you require faster delivery, please inform us at the time of order placement. Expedited orders are subject to an additional fee and depend on the current production schedule and the complexity of the parts. By prioritizing your order, we can often reduce the lead time to 1-7 days.
Our team is committed to meeting your deadlines and ensuring that you receive your parts on time, even for urgent projects. Please contact us directly to discuss your specific requirements and expedited options.
How Do We Ensure Consistency and Quality for Each Batch of Parts?
Quality Control Measures:
Advanced Inspection Tools: Utilization of CMMs (Coordinate Measuring Machines), laser scanners, and precision gauges to measure critical dimensions and geometries.
In-Process Monitoring: Continuous monitoring during machining processes to detect and correct deviations in real-time.
Material Verification: Comprehensive material testing, including chemical composition and mechanical property analysis, to ensure conformity with specifications.
Surface Finish Analysis: Employing profilometers and other surface finish measurement tools to guarantee that all parts meet required surface quality standards.
Environmental Controls: Maintaining a controlled environment in production areas to minimize the impact of temperature and humidity variations on machining accuracy.
Ensuring Consistency and Quality for Each Batch:
Standard Operating Procedures (SOPs): Strict adherence to standardized processes for each operation to ensure uniformity across all production stages.
First Article Inspection (FAI): Conducting thorough inspections on the first piece of each batch to verify that it meets all specified requirements before proceeding with full-scale production.
Statistical Process Control (SPC): Applying SPC techniques to monitor and control the manufacturing process, ensuring that variations are kept within acceptable limits.
Lot Traceability: Implementing comprehensive traceability systems to track materials and processes for each batch, allowing for easy identification and resolution of any quality issues.
Final Inspection and Testing: Performing rigorous final inspections and functional tests on all parts before shipment to confirm that they meet client specifications and quality standards.
Our commitment to stringent quality control measures ensures that you receive consistent, high-quality parts in every batch, supporting your projects’ success and reliability.
Why Modo Rapid is Your Trusted Partner for PI Projects
At Modo Rapid, we combine extensive experience, advanced technology, and a skilled team to deliver high-quality PI parts.
- Rich Experience: Over a decade in PI machining across aerospace, medical, and industrial applications.
- Advanced CNC Technology: Cutting-edge equipment for precision and efficiency in complex geometries.
- Skilled Team: Expert engineers and technicians dedicated to quality and overcoming PI’s unique challenges.
- Stringent Quality Control: Rigorous measures at every stage ensure consistent, reliable parts.
- Customer-Centric Approach: Tailored solutions with open communication and collaboration.
- Innovative Solutions: Continuous investment in R&D for advanced, competitive solutions.
Client Feedback & Reviews
Ensuring Your Compliance with Environmental and Industry Standards
At Modo Rapid, we prioritize your need for environmentally responsible and industry-compliant manufacturing processes.
Meeting Your Environmental and Industry Standards: Our operations are designed to align with stringent environmental and industry regulations, ensuring that your projects not only meet but exceed these standards.
Certifications That Matter to You:
- ISO 9001: Guaranteeing consistent quality and continuous improvement in every product you receive.
- ISO 14001: Demonstrating our commitment to environmental management, so you can trust our sustainable practices.
- RoHS Compliance: Ensuring our materials are free from hazardous substances for your safety and peace of mind.
- REACH Compliance: Managing chemicals responsibly in our products to meet your regulatory requirements.
- IATF 16949: Meeting the rigorous quality management standards required for the automotive industry, ensuring the highest quality for your automotive projects.
FAQ
Polyimide (PI) is highly valued for its exceptional thermal stability, withstanding temperatures above 300°C (572°F). It also offers outstanding chemical resistance, making it suitable for applications involving exposure to harsh chemicals. Additionally, PI provides excellent electrical insulation and maintains its mechanical properties under extreme conditions, making it ideal for aerospace, electronics, and automotive industries
Machining Polyimide can be challenging due to its high hardness and sensitivity to heat buildup. To mitigate these issues, Modo Rapid uses sharp cutting tools, applies appropriate coolants to manage heat, and ensures precise workholding to avoid deformation. Additionally, Modo Rapid’s expertise in machining tight tolerances and minimizing material wastage ensures high-quality results while controlling costs
CNC machined Polyimide parts are commonly used in industries requiring high-performance materials. Applications include aerospace components like thermal shields and engine parts, electronics such as flexible printed circuits and insulating films, and automotive under-hood components. Polyimide is also used in medical devices, microelectronics, and even space exploration due to its durability in extreme environments
Contamination prevention is critical, especially for applications in aerospace and medical sectors. Modo Rapid ensures that only plastics are machined in specific environments, with any metalwork being processed separately. This segregation prevents cross-contamination and maintains the integrity of the Polyimide parts
