Precision 5-Axis CNC Plastic Machining Services
Advanced CNC plastic machining services for high-performance engineering applications. Lehigh Valley Plastics is an ISO 9001:2015 certified manufacturer of precision plastic components serving Aerospace, Defense, Medical Device, and Semiconductor industries throughout the Lehigh Valley, Pennsylvania and nationwide.
ISO 9001:2015
Certified Quality Systems
5-Axis CNC
Advanced machining centers
±0.001″ Tolerance
Precision capability
FDA Compliant
Medical-grade materials
Advanced Plastic Milling and Turning in the Lehigh Valley
CNC plastic machining services at Lehigh Valley Plastics utilize advanced 5-axis CNC machining centers, precision milling equipment, and computer-controlled turning operations to manufacture complex plastic components from high-performance engineering polymers. LVP facility operations include advanced 5-axis CNC machining, milling, and turning for thermoplastics, serving aerospace, defense, medical device, and semiconductor manufacturing applications requiring dimensional accuracy to ±0.001″ tolerances and complete material traceability through ISO 9001:2015 certified quality systems.
5-Axis CNC Machining Capabilities
Five-axis CNC machining enables complex geometries, compound angles, and continuous surface machining in a single setup, reducing programming time, improving dimensional accuracy, and eliminating multiple setups that introduce cumulative tolerance stack-up errors.
- Continuous 5-Axis Machining: Simultaneous motion across all five axes for complex contoured surfaces, undercuts, and compound angles
- 3+2 Indexed Positioning: Fixed-angle positioning enabling access to multiple faces without manual repositioning
- Reduced Setup Time: Complete machining in single operation eliminating fixturing changes and improving throughput
- Improved Surface Finish: Tool perpendicularity optimization and reduced tool deflection producing superior surface quality
- Complex Geometry Capability: Aerospace brackets, medical device housings, and sculptured surfaces requiring multi-sided access
Applications: Aerospace structural brackets, medical device enclosures, semiconductor processing components, and defense system housings requiring complex geometries with tight tolerances.
Precision Milling & Turning Services
3-Axis CNC Milling:
Vertical machining centers for precision pocketing, profiling, drilling, and face milling operations on flat components, panels, and structural parts. Ideal for high-volume production with consistent dimensional accuracy.
CNC Turning & Swiss Screw Machining:
Precision turning operations for cylindrical components, bushings, shafts, and micro-components to 0.125″ diameter. Swiss-type screw machines provide exceptional concentricity and length-to-diameter capabilities for medical pins and precision fasteners.
Multi-Spindle Operations:
Simultaneous machining operations reducing cycle times for high-volume production requirements while maintaining statistical process control and dimensional repeatability across production batches.
Large-Format CNC Routing:
The Bethlehem, PA facility utilizes CR Onsrud CNC routers for large-scale plastic fabrication, cutting sheet materials up to 60″ x 120″ with precision profiling, nesting optimization, and complex 2.5D contour cutting for panels and structural components.
High-Performance Plastic Components for Aerospace and Defense
Lehigh Valley Plastics serves the global aerospace and defense sectors with high-performance components and materials meeting stringent dimensional, material, and regulatory requirements. Our advanced CNC machining capabilities support mission-critical applications requiring documented traceability, material certifications, and compliance with AS9100 quality standards.
Multi-axis machining centers, temperature-controlled manufacturing environments, and CMM inspection systems ensure dimensional consistency for aerospace structural components, defense system housings, and flight-critical applications demanding reliability and precision.
View Aerospace Capabilities →Precision Tolerances & Surface Finish Capabilities
Achievable Machining Tolerances
| Specification | Standard Tolerance | Precision Capability |
|---|---|---|
| Linear Dimensions | ±0.005″ (0.127mm) | ±0.001″ (0.025mm) |
| Flatness | 0.005″ per inch | 0.001″ per inch |
| Parallelism | ±0.005″ | ±0.001″ |
| Perpendicularity | ±0.005″ | ±0.002″ |
| Concentricity | ±0.003″ | ±0.0005″ |
| Roundness (Circularity) | ±0.003″ | ±0.0005″ |
All tolerances verified through CMM inspection with PC-DMIS software. GD&T specifications interpreted per ASME Y14.5-2018 standards. NIST-traceable calibration documentation provided.
Surface Finish Standards
| Finish Type | Ra (μin) | Applications |
|---|---|---|
| Standard Machined | 63-125 | Structural components, housings |
| Fine Machined | 32-63 | Bearing surfaces, sealing faces |
| Precision Machined | 16-32 | Optical components, critical fits |
| Ground/Lapped | 8-16 | Ultra-precision applications |
| Polished | 4-8 | Medical devices, cleanroom parts |
Surface finish achieved through toolpath optimization, cutting parameter control, and secondary operations including buffing, polishing, and vapor polishing for optical-quality surfaces.
ISO 9001:2015 Certified Quality Systems
Every machined component is manufactured under documented quality procedures with material traceability, in-process inspection, and final dimensional verification. Our ISO 9001:2015 certification ensures consistent process control, continuous improvement, and accountability throughout the manufacturing cycle.
CMM inspection, optical comparators, and precision measurement equipment verify critical dimensions with documented inspection reports. Statistical process control (SPC) monitors production consistency, and PPAP packages support automotive and aerospace customer requirements.
View Quality Systems →
High-Performance Engineering Plastics for CNC Machining
Lehigh Valley Plastics machines advanced engineering polymers selected for mechanical strength, temperature resistance, dimensional stability, and chemical compatibility. Material expertise spans commodity thermoplastics through ultra-high-performance polymers for demanding aerospace, medical, and industrial applications.
ABS Plastic Machining
Continuous Use Temperature: 180°F (82°C)
Tensile Strength: 6,500 psi
Impact Strength: 10-12 ft-lb/in (Izod notched)
Machining Characteristics:
ABS plastic provides excellent machinability with minimal tool wear, clean chip formation, and superior surface finish capability. Machines well at moderate speeds (1,500-3,000 SFM) with carbide or HSS tooling. Low internal stress reduces warping during machining operations.
Applications:
Equipment housings, protective covers, automotive interior components, consumer product prototypes, and jigs/fixtures. Excellent for large structural components requiring impact resistance and aesthetic surface finish.
Key Properties:
- Superior impact resistance at room temperature
- Excellent dimensional stability and rigidity
- Outstanding surface finish for painting/plating
- Cost-effective for large components
PEEK Plastic Machining
Continuous Use Temperature: 480°F (250°C)
Tensile Strength: 14,500 psi
Coefficient of Friction: 0.31 (dynamic vs steel)
Machining Characteristics:
PEEK plastic requires sharp carbide tooling, positive rake angles, and consistent chip evacuation to prevent heat buildup. Optimal cutting speeds 400-800 SFM with continuous coolant recommended for precision tolerances. Excellent dimensional stability during and after machining.
Applications:
Semiconductor processing equipment, aerospace structural components, medical implantable devices, high-temperature bearings, and chemical processing components. Essential for applications exceeding temperature/chemical limits of conventional engineering plastics.
Key Properties:
- Exceptional chemical resistance to acids, bases, solvents
- Superior wear resistance (K-factor: 50-150)
- Autoclavable, USP Class VI certified grades available
- Inherent flame resistance without additives
Nylon Plastic Machining
Continuous Use Temperature: 200°F (93°C)
Tensile Strength: 12,000 psi
Coefficient of Friction: 0.35-0.40 (dynamic vs steel)
Machining Characteristics:
Nylon plastic machines best with sharp tooling, high cutting speeds (2,000-4,000 SFM), and light depths of cut. Moisture content affects dimensional stability—material should be pre-conditioned or machined dry with post-machining dimensional verification after moisture equilibration.
Applications:
Wear pads, roller bearings, sprockets, bushings, gears, material handling components, and industrial machinery parts. Ideal for high-impact, high-fatigue applications where self-lubricating properties eliminate external lubrication requirements.
Key Properties:
- Excellent impact strength across temperature range
- Superior fatigue resistance for cyclic loading
- Self-lubricating bearing surface properties
- Cost-effective for high-volume production
Delrin / Acetal (POM)
Continuous Use Temperature: 180°F (82°C)
Tensile Strength: 10,000 psi
Coefficient of Friction: 0.20 (dynamic vs steel)
Machining Characteristics:
Delrin provides exceptional machinability with low cutting forces, excellent chip formation, and superior surface finish. Machines at high speeds (3,000-5,000 SFM) with minimal tool wear. Low moisture absorption ensures dimensional stability.
Applications:
Precision gears, bushings, bearings, conveyor components, food processing equipment, medical device housings, and high-precision mechanisms. Preferred for applications requiring tight tolerances and low coefficient of friction.
Key Properties:
- Lowest coefficient of friction among engineering plastics
- Excellent dimensional stability and creep resistance
- FDA compliant grades for food contact
- Superior machinability and surface finish
Ultem (PEI)
Continuous Use Temperature: 340°F (170°C)
Tensile Strength: 15,200 psi
Flame Resistance: FAR 25.853 compliant
Machining Characteristics:
Ultem requires carbide tooling, moderate speeds (800-1,500 SFM), and controlled feed rates to prevent heat buildup and surface burning. Transparent amber color allows visual inspection of internal features during machining.
Applications:
Aircraft interior components, medical sterilization trays, semiconductor wafer handling, high-strength electrical insulators, and flame-retardant structural housings. Essential for aerospace applications requiring FAR 25.853 certification.
Key Properties:
- Exceptional strength-to-weight ratio
- Steam sterilizable (270°F repeated cycles)
- Inherent flame resistance, low smoke generation
- USP Class VI biocompatible grades available
UHMW-PE
Continuous Use Temperature: 180°F (82°C)
Tensile Strength: 3,100 psi (high elongation)
Coefficient of Friction: 0.10 (lowest among thermoplastics)
Machining Characteristics:
UHMW plastic requires very sharp tooling and high rake angles due to material toughness and tendency to “flow” rather than chip. Best machined at low speeds (400-800 SFM) with aggressive chip evacuation. Excellent abrasion resistance causes accelerated tool wear.
Applications:
Wear strips, conveyor guides, chute liners, impact pads, material handling components, and marine applications. Ideal for sliding, wear, and impact applications where low friction and abrasion resistance are critical.
Key Properties:
- Lowest coefficient of friction (0.10 vs steel)
- Exceptional abrasion and wear resistance
- Self-lubricating, non-stick surface properties
- FDA compliant for food contact applications
FDA-Compliant and Biocompatible Plastic Machining
Lehigh Valley Plastics provides FDA-compliant and biocompatible plastic machining for medical and food-grade applications requiring material traceability, USP Class VI certifications, and regulatory compliance documentation. Our quality systems support medical device manufacturers, pharmaceutical processing equipment, and food contact applications demanding the highest material purity and process control standards.
Medical-grade PEEK, Ultem, and Acetal materials machined under controlled conditions with material certificates, biocompatibility test reports, and FDA compliance statements supporting regulatory submissions and quality system audits.
View Medical Capabilities →Engineering Material Comparisons: Coefficient of Friction & Wear Resistance
What is the coefficient of friction for common bearing plastics?
The coefficient of friction (COF) determines how easily plastic bearing surfaces slide against metal counterfaces. Lower COF values indicate superior self-lubricating properties, reduced wear, and lower operating temperatures in dry-running bearing applications.
| Material | Dynamic COF (vs Steel) | Wear Factor (K x 10⁻¹⁰) |
|---|---|---|
| UHMW-PE | 0.10 | 10-30 (Extremely Low) |
| Acetal (Delrin) | 0.20 | 80-120 (Excellent) |
| Torlon (PAI) | 0.15-0.25 | 20-50 (Extremely Low) |
| PEEK | 0.31 | 50-150 (Very Low) |
| Nylon 6/6 | 0.35-0.40 | 60-100 (Very Good) |
| Bronze (Reference) | 0.16 (lubricated) | Variable (requires lubrication) |
Application Guidance: UHMW-PE and Acetal provide the lowest friction for high-speed, light-load applications. Torlon and PEEK handle extreme temperatures and heavy loads. Nylon offers balanced performance at economical cost. All plastic bearings eliminate external lubrication requirements critical for food processing, medical devices, and cleanroom environments.
How does temperature resistance compare across engineering plastics?
Continuous use temperature defines the maximum operating temperature where plastics maintain mechanical properties and dimensional stability over extended periods. Heat deflection temperature (HDT) indicates short-term thermal performance under load.
| Material | Continuous Use Temp | Heat Deflection Temp (264 psi) |
|---|---|---|
| Torlon (PAI) | 500°F (260°C) | 525°F (274°C) |
| PEEK | 480°F (250°C) | 315°F (157°C) |
| Ultem (PEI) | 340°F (170°C) | 392°F (200°C) |
| Nylon 6/6 | 200°F (93°C) | 210°F (99°C) |
| Acetal (Delrin) | 180°F (82°C) | 252°F (122°C) |
| ABS Plastic | 180°F (82°C) | 203°F (95°C) |
Selection Criteria: Torlon and PEEK essential for extreme temperature applications (>400°F) including semiconductor processing and aerospace. Ultem provides balanced heat resistance with flame retardancy for aircraft interiors. Nylon and Acetal suitable for most industrial applications below 200°F. Temperature spikes, chemical exposure, and mechanical loads all affect material selection.
Precision CNC Machining for Mission-Critical Industries
Aerospace & Defense Manufacturing
Materials: Ultem (PEI), PEEK, Torlon, flame-retardant engineering plastics meeting FAR 25.853 standards for aircraft interior components and flight-critical applications.
Machining Capabilities: 5-axis CNC machining for complex aerospace brackets, structural components, electrical insulators, and lightweight panel assemblies. Precision tolerances to ±0.001″ with GD&T interpretation per ASME Y14.5 standards.
Compliance & Documentation:
- FAR 25.853 flame-smoke-toxicity certifications
- AS9100 quality system compatibility
- Material traceability with batch-specific certifications
- First-article inspection reports (FAIR) for new programs
- PPAP documentation for production qualification
Medical Device & Biomedical Applications
Materials: USP Class VI certified PEEK, Ultem, Acetal, and FDA CFR Title 21 compliant polymers for direct patient contact, surgical instruments, and pharmaceutical processing equipment.
Biocompatible Machining: Medical-grade materials machined in controlled environments with documented cleaning protocols, operator training records, and process validation supporting ISO 13485 compliance and FDA regulatory submissions.
Quality Documentation:
- USP Class VI biocompatibility certificates
- FDA compliance statements and material certifications
- Material Safety Data Sheets (SDS) and extractables data
- Autoclave validation testing (270°F steam cycles)
- Design History File (DHF) support documentation
Semiconductor & Electronics Manufacturing
Materials: PEEK, PPS, PVDF, ultra-high purity plastics with low outgassing, minimal particle generation, and plasma resistance for cleanroom fabrication equipment.
Ultra-Precision Machining: Components for wet benches, chemical delivery systems, wafer handling equipment, and process gas distribution requiring particle-free surfaces and dimensional accuracy to ±0.0005″ for critical sealing interfaces.
Cleanroom Requirements:
- Material purity certifications and extractables data
- Particle-free machining and handling protocols
- Cleanroom packaging (ISO Class 5-8 compatible)
- Chemical resistance verification for aggressive etchants
- Dimensional stability in vacuum and plasma environments
Industrial Manufacturing & Heavy Equipment
Materials: Acetal (Delrin), Nylon 6/6, UHMW-PE, and self-lubricating engineering plastics for high-load bearing surfaces, wear components, and material handling applications.
Production Machining: High-volume CNC machining for bearings, wear pads, bushings, sprockets, gears, and conveyor components. Statistical process control ensures dimensional consistency across production batches of 100-10,000+ components.
Performance Benefits:
- Coefficient of friction: 0.10-0.35 (self-lubricating)
- Extended service life vs metal in contaminated environments
- Corrosion resistance eliminating galvanic concerns
- Noise reduction and vibration damping properties
- Weight reduction for improved energy efficiency
Frequently Asked Questions About CNC Plastic Machining
What tolerances can CNC plastic machining achieve?
Standard CNC machining tolerances are ±0.005″ (0.127mm) with precision capability to ±0.001″ (0.025mm) on critical dimensions. Achievable tolerances depend on material properties (thermal expansion, moisture absorption), part geometry, feature size, and inspection requirements. GD&T specifications interpreted per ASME Y14.5 standards with CMM verification and documented inspection reports.
Do you provide ISO 9001 quality documentation?
Yes. Lehigh Valley Plastics is ISO 9001:2015 certified. All components manufactured under documented quality procedures with material certifications, dimensional inspection reports (including CMM data), first-article inspection reports (FAIR), and full traceability documentation. PPAP packages available for automotive and aerospace applications requiring AS9100 compatibility.
What is the difference between 3-axis and 5-axis CNC machining?
3-axis CNC machining moves cutting tools along X, Y, and Z linear axes, ideal for flat parts and simple geometries. 5-axis CNC machining adds rotational axes (A and B) enabling tool approach from any angle, machining complex contours, undercuts, and compound angles in single setup. 5-axis reduces setup time, improves accuracy, and enables complex aerospace/medical geometries impossible with 3-axis equipment.
Can you machine FDA compliant materials for medical devices?
Yes. We machine USP Class VI certified materials including medical-grade PEEK, Ultem, and Acetal meeting FDA CFR Title 21 requirements for biocompatibility and direct patient contact. Material certifications, USP Class VI certificates, biocompatibility test reports, and compliance documentation provided supporting regulatory submissions, Design History Files (DHF), and quality system audits.
What is your typical lead time for CNC machined components?
Prototype quantities (1-10 pieces) typically ship in 5-10 business days depending on complexity and material availability. Production runs (100-1,000+ pieces) require 2-4 weeks for manufacturing, inspection, and documentation. Expedited service available for urgent requirements. Repeat orders benefit from reduced lead times through established tooling, fixturing, and process documentation.
Which plastic has the lowest coefficient of friction for bearing applications?
UHMW-PE provides the lowest coefficient of friction (0.10 vs steel) among engineering plastics, ideal for light-load, high-speed applications. Acetal (0.20 COF) offers better dimensional stability and creep resistance for precision bearing applications. Torlon (0.15-0.25 COF) handles extreme temperatures and heavy loads. Material selection depends on load (PV limits), speed, temperature, and chemical exposure.
Do you offer Design for Manufacturability (DFM) consultation?
Yes. Our engineering team provides DFM analysis during quotation, identifying opportunities to optimize part geometry, specify appropriate tolerances, recommend cost-effective materials, reduce cycle times, and improve dimensional stability. This consultation helps reduce unit costs and manufacturing complexity while maintaining functional requirements and design intent.
Where is Lehigh Valley Plastics located?
Our 55,000 square-foot manufacturing facility is located at 187 North Commerce Way, Bethlehem, Pennsylvania 18017, serving customers throughout the Lehigh Valley (Allentown, Bethlehem, Easton), Philadelphia region, and nationwide. Climate-controlled manufacturing environment ensures dimensional stability for precision plastic components.
Request a Quote for Precision CNC Plastic Machining Services
Contact Lehigh Valley Plastics for advanced CNC machining services including 5-axis machining, precision milling, and CNC turning. ISO 9001:2015 certified quality systems, expert material selection, and comprehensive engineering support for Aerospace, Defense, Medical Device, Semiconductor, and Industrial applications requiring documented traceability and regulatory compliance.