One of the best ways to fabricate Teflon parts is CNC machining. This article looks at the ins and outs of machining Teflon: its material properties, the advantages of machining it, common applications, and more.
What is Teflon?
PTFE is a thermoplastic and a fluoropolymer of tetrafluoroethylene. The name ‘Teflon’ is a brand name of American chemical company Chemours, a spinoff from chemical giant DuPont (now DowDuPont). Interestingly, the material was initially discovered by mistake.
A white solid at room temperature, PTFE consists of carbon and fluorine only. It is hydrophobic, has incredibly low friction, and is non-reactive due to the very strong bonds between carbon and fluorine, one of the strongest existing bonds in organic chemistry. Due to its low friction — it is the only surface a gecko cannot stick to! — Teflon is often used as a lubricant.
The melting point of PTFE is 327 °C, and other material properties include strength, toughness, and self-lubrication at low temperatures.
Polytetrafluoroethylene (PTFE), most commonly known by the brand name Teflon, is a synthetic fluoropolymer thermoplastic that can be used for a range of applications, from non-stick frying pans to medical devices.
Resistant to chemicals and stable even at high temperatures, Teflon is one of the popular CNC machining and milling plastics for many specific applications, despite its so-so mechanical properties. As is the case with non-stick frying pans, it is sometimes used as a coating rather than a base material, and it can be manufactured in several ways.
Advantages of machining Teflon
There are several advantages to Teflon machining, including inherent material advantages of PTFE and advantages derived from the process of machining.
Material advantages of machining Teflon include:
Chemically resistant
UV/weather resistant
Water resistant; hydrophobic
High impact strength
Good electrical insulator
Flexible even at low temperatures
Thermal stability between -260°C and 260°C
Very low coefficient of friction
Low flammability
Food-safe
Easy to clean
Process advantages of machining Teflon include:
Easily machinable due to softness and density
Excellent thermal stability prevents part deformation and tool clogging
Limitations of machining Teflon
High coefficient of expansion
Stress creep
Difficult to achieve tight tolerances
Poor mechanical properties
Poor dimensional stability
Risk of burrs due to material softness
Applications of Teflon machining
Teflon is not the most versatile material for CNC machining, but it has some important niche applications due to its desirable properties like thermal stability and a low friction coefficient.
About half of all PTFE in the world is used for wire insulation, but wiring and its insulation is not made using CNC machines. The other most well-known use of Teflon is for non-stick coatings on aluminum cookware; in this case, Teflon in its liquid form is sprayed or rolled onto the etched metal surface. In general, Teflon-lined cookware is not machined.
Nonetheless, CNC machining is useful for manipulating Teflon in its solid form. Teflon parts suitable for machining include industrial components like gears, bushings, fittings, and valves.
Some commonly CNC machined PTFE parts, used in industries like medicine, food processing, science, and aerospace, include:
Ventile
Fittings
Bearings
Bushings
Manifolds
Insulators
Gears
O-rings
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