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Machining Guidelines - Sawing

Sawing Guidelines for Plastics

Essential information for successful sawing operations on plastic materials

Sawing plastic materials requires specific blade designs and cutting parameters to achieve clean cuts without melting, chipping, or crazing. The unique thermal and mechanical properties of plastics necessitate approaches different from those used for metals or wood.

Key Considerations for Sawing Plastics:

  • Blade Type: Carbide-tipped blades with specialized tooth geometry are recommended for most plastic materials.
  • Tooth Design: Triple-chip tooth design helps prevent chipping in brittle plastics and ensures smooth cuts.
  • Hook Angle: A low positive hook angle (5-10°) provides the best results, preventing aggressive grabbing.
  • Tooth Pitch: Use 4-10 teeth per inch (TPI) depending on material thickness. Thinner materials require finer tooth pitch.
  • Cutting Speed: Lower speeds are generally better for plastics to prevent heat buildup and melting at the cut edge.

The table below provides specific sawing parameters for different plastic materials based on their machinability ratings and physical properties.

Note: Properly support the material on both sides of the cut to prevent vibration and edge chipping. For acrylic and other brittle plastics, use masking tape along the cut line to reduce the risk of chipping.

Troubleshooting Guide

Solutions for common issues with plastic machining operations

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SAWING
Sawing Parameters Diagram
Plastic Material Trade Names Machinability
(Unfilled)
1 = Easiest
10 = Hardest		 Machinability
(CA, GF Filled)
1 = Easiest
10 = Hardest		 Belt
Saw

Clearance
Angle		 Belt
Saw

Rake
Angle		 Circular
Saw

Clearance
Angle		 Circular
Saw

Rake
Angle		 General
Sawing

Material
Thickness		 General Sawing

Tooth
Form		 General
Sawing

Pitch
teeth/in.		 General
Sawing

Band
Speeds
Acrylonitrile Butadiene Styrene (ABS) Tecaran®
GEHR ABS®
ABSylux®		 2 15-30 5-8 15-30 5-8 < 0.5"
0.5" - 1.0"
1.0" - 3.0"
> 3.0"		 Precision
Precision
Butress
Butress		 10-14
6
3
3		 4000
3500
3000
2500
Polyvinyl Chloride
PVC Type 1 & 2
Chlorinated Polyvinyl Chloride (CPVC)		 PVC-CAW
Vintec® I & II
Corzan® - resin		 2 15-30 5-8 15-30 5-8 < 0.5"
0.5" - 1.0"
1.0" - 3.0"
> 3.0"		 Precision
Precision
Butress
Butress		 10-14
6
3
3		 4000
3500
3000
2500
Polyphenylene Oxide (PPO) Tecanyl®
GEHR PPO®
SustaPPO®		 2 15-30 5-8 15-30 5-8 < 0.5"
0.5" - 1.0"
1.0" - 3.0"
> 3.0"		 Precision
Precision
Butress
Butress		 10-14
6
3
3		 4000
3500
3000
2500
Polymethyl-Methacrylate (PMMA) Acrylics Plexiglas®
Acrylite®
Lucite®		 2 15-30 5-8 15-30 5-8 < 0.5"
0.5" - 1.0"
1.0" - 3.0"
> 3.0"		 Precision
Precision
Butress
Butress		 10-14
6
3
3		 4000
3500
3000
2500
Polyethylene (PE)
LDPE, HDPE, UHMW-PE		 Tecafine®
UHMWPE / Hy-pact®
TIVAR®
Polystone®		 1 20-30 2-5 20-30 6-10 < 0.5"
0.5" - 1.0"
1.0" - 3.0"
> 3.0"		 Precision
Precision
Butress
Butress		 10-14
6
3
3		 3000
2500
2000
1500
Polypropylene (PP) Tecapro®
Proteus®
Polystone®		 2 20-30 2-5 20-30 6-10 < 0.5"
0.5" - 1.0"
1.0" - 3.0"
> 3.0"		 Precision
Precision
Butress
Butress		 10-14
6
3
3		 4000
3500
3000
2500
Nylon Polyamide (PA)
Type 6, Type 66, Type 46
Type 11, Type 12
Type 66 - Kevlar® Filled		 Nycast®
Tecamid® / Nylatron®
Sustamid® / ZL®1100, 250
Hydlar®		 1 15-30 0-5 15-30 0-8 < 0.5"
0.5" - 1.0"
1.0" - 3.0"
> 3.0"		 Precision
Precision
Butress
Butress		 10-14
6
3
3		 3000
2500
2000
1500
Acetal Polyoxymethylene (POM)
Copolymer (POM-C)
Homopolymer (POM-H)		 Delrin® / Tecaform®
GEHR Acetal® / Acetron®
Sustarin®
ZL® 900		 1 20-30 0-5 5-10 0-10 < 0.5"
0.5" - 1.0"
1.0" - 3.0"
> 3.0"		 Precision
Precision
Butress
Butress		 10-14
6
3
3		 3000
2500
2000
1500
Polycarbonate (PC) Tecanat®
Tuffak® / Sustanat®
Zelux® / ZL® 1600
Lexan® - Resin		 2 15-30 5-8 15-30 5-8 < 0.5"
0.5" - 1.0"
1.0" - 3.0"
> 3.0"		 Precision
Precision
Butress
Butress		 10-14
6
3
3		 4000
3500
3000
2500
Sulfones
Polysulfone (PSU)
Polyphenylsulfone (PPSU)		 Tecason®
Sultron®
Sustason®
Udel®, Radel® - resins		 3 15-30 0-4 15-30 0-15 < 0.5"
0.5" - 1.0"
1.0" - 3.0"
> 3.0"		 Precision
Precision
Butress
Butress		 10-14
6
3
3		 4000
3500
3000
2500
Polyetherimide (PEI) TecaPEI®,
Duratron®
SustaPEI® ZL® 1000
Ultem® 1000 - resin		 3 15-30 0-4 15-25 0-15 < 0.5"
0.5" - 1.0"
1.0" - 3.0"
> 3.0"		 Precision
Precision
Butress
Butress		 10-14
6
3
3		 3000
2500
2000
1500
Polyethylene-terephthalate (PET-P)
Polyester - precrystallized
Polybutylene-terephthalate (PBT)		 GEHR PET®
TecaPET® / Ertalyte®
Sustadur® / ZL® 1400
Hydex®		 3 15-40 0-8 10-15 0-15 < 0.5"
0.5" - 1.0"
1.0" - 3.0"
> 3.0"		 Precision
Precision
Butress
Butress		 10-14
6
3
3		 5000
4300
3500
3000
Polyetheretherketone (PEEK)
PAEK, PEEK, PEK, PEKK, PEKEKK
CA30%, GF30%		 TecaPEEK® / GEHR PEEK®
Ketron®
SustaPEEK®
ZL® 1500		 5 7 15-30 0-5 15-30 0-10 < 0.5"
0.5" - 1.0"
1.0" - 3.0"
> 3.0"		 Precision
Precision
Butress
Butress		 10-14
6-8
3
3		 4000
3500
3000
2500
Polytetrafluoroethylene (PTFE)
Unfilled, Glass, or Mica Filled
Ethylene TetrafluoroEthylene (ETFE)		 Teflon® - Resin
Fluorosint® / Rulon®
Tefzel® - Resin		 1 3 20-30 2-8 20-30 6-10 < 0.5"
0.5" - 1.0"
1.0" - 3.0"
> 3.0"		 Precision
Precision
Butress
Butress		 10-14
6-8
3
3		 3000
2500
2000
1500
Polyvinylidene fluoride (PVDF)
Fluorinated Ethylene Propylene (FEP)
Polychlorotrifluoroethylene (PCTFE)
Perfluroalkoxy (PFA)		 Kynar® - Resin
Kel-F®, Neoflon® - Resins
Hyflon® - Resin
Halar® - Resin		 2 20-30 5-8 5-10 0-10 < 0.5"
0.5" - 1.0"
1.0" - 3.0"
> 3.0"		 Precision
Precision
Butress
Butress		 10-14
6
3
3		 4000
3500
3000
2500
Ethylene chlorotrifluoroethylene (ECTFE)* Kynar® - Resin
Kel-F®, Neoflon® - Resins
Hyflon® - Resin
Halar® - Resin		 2 20-30 5-8 5-10 0-10 < 0.5"
0.5" - 1.0"
1.0" - 3.0"
> 3.0"		 Precision
Precision
Butress
Butress		 10-14
6
3
3		 4000
3500
3000
2500
Polyphenylene sulfide (PPS) Tecatron®
GEHR PPS®
Sustatron®		 5 15-30 0-5 15-30 0-10 < 0.5"
0.5" - 1.0"
1.0" - 3.0"
> 3.0"		 Precision
Precision
Butress
Butress		 10-14
6-8
3
3		 5000
4300
3500
3000
Polyamideimide (PAI) Tecator®
Duratron®
Torlon® - resin		 5 8 15-30 0-5 15-30 0-10 < 0.5"
0.5" - 1.0"
1.0" - 3.0"
> 3.0"		 Precision
Precision
Butress
Butress		 10-14
6-8
3
3		 5000
4300
3500
3000
Polyimide (PI) Plavis®
Vespel®
XP-131 PI
Duratron®		 5 15-30 0-5 15-30 0-10 < 0.5"
0.5" - 1.0"
1.0" - 3.0"
> 3.0"		 Precision
Precision
Butress
Butress		 10-14
6-8
3
3		 5000
4300
3500
3000
Polybenzimidazole (PBI) / Polyetheretherketone (PEEK) Blend Celazole® TU-60 8 15-30 0-5 15-30 0-10 < 0.5"
0.5" - 1.0"
1.0" - 3.0"
> 3.0"		 Precision
Precision
Butress
Butress		 10-14
6-8
3
3		 4000
3500
3000
2500
Polybenzimidazole (PBI) / Polyetherketoneketone (PEKK) Blend Celazole® TK-60 8 15-30 0-5 15-30 0-10 < 0.5"
0.5" - 1.0"
1.0" - 3.0"
> 3.0"		 Precision
Precision
Butress
Butress		 10-14
6-8
3
3		 4000
3500
3000
2500
Polybenzimidazole (PBI) Celazole® U-60
Duratron® CU 60		 10 15-30 0-5 15-30 0-10 < 0.375" - 1.0"
1.0" - 2.0"		 Precision
Butress		 10
10		 3000
1500
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