To minimize the loss during the processing of ultra-high molecular weight polyethylene (UHMWPE) sheets, it is necessary to optimize multiple links such as material selection, cutting layout, processing methods and equipment selection. The following is a comprehensive strategy to reduce losses during processing:
- Control losses in the material selection link
Customize the required size of sheets
Customize sheets close to the finished size from suppliers to reduce secondary cutting;
Particularly suitable for batch processing of parts of the same specification.
Preferred compression molded sheets
Compression molded sheets have uniform thickness and high flatness;
Compared with extruded sheets, they are more stable and less deformed in subsequent cutting. - Reasonably optimize layout design
Use CAD + Nesting software (Nest) to optimize the nesting diagram
Automatically calculate the optimal cutting path and arrangement method;
Increase the utilization rate of residual corners to more than 90%;
Applicable software: AutoCAD + Nesting Plug-in, SigmaNEST, Cutting Optimization Pro, etc.
Unify layout direction
Keep the parts texture consistent, which is conducive to thermal expansion control and reduce scrap rate;
Especially important for multi-piece splicing structural parts or decorative panels. - Process control skills
Precision CNC processing
Use appropriate tools (recommended carbide + polished edge);
Reasonably set the speed (6000-10000rpm) and feed (0.3-0.8mm/rev);
Effectively avoid rework or scrapping caused by melting edge, overflow, and edge collapse.
Control thermal deformation
Use cooling air (oil spraying is not recommended);
Avoid local melting and deformation caused by high-speed friction.
Reduce pre-cut samples and trial and error processing
Use software simulation or laser measuring instrument to pre-check dimensions and trajectories;
Greatly reduce trial and error boards and rework rates. - Scrap reuse strategy
Collect scraps uniformly
Sort the remaining materials (small pieces, long strips, etc.) by size;
Secondary processing is gaskets, pads, sliders, baffles and other functional parts.
Production of small standard parts
Such as foot pads, seal sliders, guide rail blocks and other small batch products;
Maximize the use of scraps.
Recycling and granulation
For waste materials that cannot be processed again, they can be recycled and crushed for the production of medium and low requirement plates or molded recycled plates.
V. Standard loss control reference value
Processing method Recommended loss control value
CNC processing 5–10%
Manual cutting 10–15%
Optimized layout + precision CNC 3–5% (best)
Recycling rate of recycled materials 30–60% (scraps)