Robotics has experienced amazing developments over the past years and most of the development can be cited to the clever use of materials during production. Among such materials, the polymers and plastics can be singled out as being game-changers in the way robots are designed, assembled and functioned. The ability to differentiate between these materials and the purpose of their usage in CNC machining creates great opportunities to anyone who is interested in the robotics, engineering, or manufacturing profession.
You may not need to look far to realize that in the future you will be doing mechanical engineering work, but even just wondering how robots around you work, understanding the connection between polymers and plastics in robotic work will help you to have a better understanding of the current manufacturing practice.
Understanding the Core Difference Between Polymers and Plastics
These words are interchangeably used by many people, but there is one thing that is important to know. A polymer is a massive molecule composed of repeating structural molecules known as monomers bound by chemical bonds. Polymers represent the general term that can encompass not only natural materials such as silk, cellulose, and DNA but also the man-made materials that are produced in laboratories.
Plastics on the other hand are a special form of synthetic polymers which can be shaped or molded during heating. Plastics are also polymers, whereas not every polymer is a plastic. Such a difference is of immense importance in the production of robots since engineers are required to choose materials in accordance with specific properties and performance needs.
In nature, natural polymers have been in existence over millions of years. Trees provide rubber, cotton fibers, as well as the proteins in our bodies are all polymers. The discovery of synthetic polymers containing most of our daily plastics was the invention of man to satisfy certain industrial requirements.
Why Material Selection Matters in Robotics Manufacturing
The applications of robotics require the use of materials that are stress resistant, lightweight, and non-corrosive, as well as stability of the dimensions of the product in different circumstances. Polymers and plastics have certain advantages that qualify them as the most suitable to various components of the robots.
The old-fashioned materials such as metals are yet to be replaced by polymers and plastics which have made it possible to develop lighter, efficient and affordable robotic systems. The National Institute of Standards and Technology has estimated that in many applications, using advanced polymer composites can lower the weight of components by up to 70 percent of what would be used as a metal component and be equally strong.
The selection of various polymer materials is dependant on a number of variables that include operating temperature, chemical exposure, load carrying needs, and compatibility with manufacturing technique.
How CNC Machining Transforms Polymers and Plastics into Robotic Components
Precision manufacturing in robotics has been depended on by CNC (Computer Numerical Control) machining. This is an automated system that involves computerized controls that control machine tools which cut, drill, and shape materials in the most highly accurate way.
CNC machining has a number of unique benefits when applied to polymers and plastics. The technique enables the manufacturers to produce complex geometries that otherwise would have been hard or impossible to produce using conventional techniques in molding. This accuracy is crucial to the robotic components that should be able to fit and work correctly in thousands of cycles.
The machining process consists of feeding computer generated design files into CNC machines that cut material out of a solid block so as to generate the required shape. In the case of polymers and plastics, it usually entails specialized cutting tools and regulated speeds in order to avoid the melting and deformation of the material during the machining process.
Common Polymer Materials Used in Robotic Applications
A number of special polymer materials have been found to be efficient especially in the manufacturing of robots using CNC machining.
Acetal (Delrin) is a thermoplastic that exhibits high levels of stiffness, low friction and has high levels of dimensional stability. It is commonly employed in gears, bearings and sliding parts in the robotic joints when smooth movement is of the essence.
PEEK (Polyetheretherketone) is a high-performance polymer, which is able to tolerate very high and very low temperatures and also undergoing extreme chemical conditions. Robotic systems used in industries are those systems that employed PEEK as their components due to their ability to withstand wear and tear.
Nylon provides a compromise of strength, flexibility and cost-effectiveness. It is regularly machined in the form of bushings, spacers and structural parts that do not demand the high performance nature of more costly materials.
Polycarbonate offers a high impact resistance and optical clarity, which makes it a great choice of material to use in protective housings, sensor covers, and components requiring high strength and transparency.
Real-World Applications of CNC Machined Polymers in Robotics
There are numerous applications of modern robotic systems using CNC machined polymers and plastics. Cobots (collaborative robots) used in factories with human workers are also characterized by polymer housings, which decrease the weight but ensure sufficient protection to internal electronics.
Medical robots exploit the fact that polymer components of surgical instruments are high precision machined and that biocompatibility and resistance to sterilization are the two most important criteria. The materials can be sterilized and reused without corrosion as some alternatives made of metals could occupy over time.
Drones and autonomous cars are overly dependent on lightweight polymer materials to ensure the greatest battery capacity and range. Each gram saved on selecting the smart materials will directly translate into better performance and a long life cycle.
Robotics student kits based on CNC machined plastics are common in educational applications of robotics since they are cheap, safe, and can be modified to suit other projects.
The Manufacturing Process for Robotic Polymer Components
There is a organized process to the production of robotic components into polymers and plastics using CNC machining. Engineers start with the design of the components in CAD (Computer-Aided Design) software, where stress points, assembly requirements and material properties are taken into consideration.
The design is then translated into CNC programming code which is followed by the machining equipment. Depending on the polymer type that is to be machined, and the required surface finish, operators choose the right cutting tools.
In machining, a combination of cutting speed and temperature of the tool helps prevent the plastic to melt or develop any internal stress that may cause the plastic to warp. Large polymers need particular coolants or air cooling systems to be kept in the most optimal cutting environment.
Components may be machined, and then finished, such as deburred or polished or coated, to final specifications. The quality control process allows dimensional control, generally to within a few thousandths of an inch.
Advantages of Using Polymers and Plastics Over Traditional Materials
One of the greatest advantages of the use of polymers in robotics is weight reduction. Smaller motors are needed to operate lighter robots, less energy is used, and in most cases; they can run faster without loss of strength.
Corrosion resistance does away with numerous maintenance headaches with metal components. The use of robots in environments that are humid, chemical, or marine would greatly benefit due to polymer components that do not rust and degrade with environmental exposure.
Certain polymers are suitable in robotics components that are in electrical proximity due to their electrical insulation properties. This insulation will help to make design easier and minimize the necessity of adding extra protective measures.
Polymers have cost effectiveness and machining in the manufacturing of robotics used in the production process. Most polymer materials are cheaper than metals and machine faster which helps in cutting on the total cost of manufacture.
Challenges in Working With Polymers and Plastics
Polymers and plastics pose special problems in CNC machining despite the benefits they offer. It is important that the temperature is controlled when cutting. Too much heat may lead to the melting of the material, poor surface finish and internal stresses leading to subsequent deformation.
Some of the polymers that absorb moisture in the air may pose a problem of dimensional stability. The components can vary a bit in size depending on the humidity in the environment, and this factor should be taken into consideration by the engineers in the design specifications.
Less strength than metals implies that polymers cannot be used in all applications. Even components of high-load bearing or extreme mechanical stress might need to be provided with metal alternatives.
In machining some filled polymers with glass fibers or other reinforcing materials tool wear may in fact be accelerated. These hardening agents are abrasive and make the polymer tougher though they can easily cut cutting tools dull.
Future Trends in Polymer Applications for Robotics
The robotics market keeps spreading the limits of the possibility of using advanced polymer materials. Scientists are working on new polymer composites that use carbon nanotubes or graphene to get strength to weight ratios competitive to metals.
Responsible polymers are smart polymers that vary in their properties according to the environmental conditions. Such materials may facilitate robots which change their mechanical properties according to temperature, moisture, or electricity.
The use of recyclable and biodegradable polymers is becoming popular as the environment is becoming a factor in the decisions made in manufacturing. Creating robotic parts with eco-friendly materials without compromising on performance is a big engineering problem with great connotations.
Additive manufacturing with CNC finishing could be more popular, and polymer components could be rapidly prototyped with the accuracy finishing CNC machining makes possible.
Frequently Asked Questions About Polymers and Plastics in Robotics
How do polymers differ in practical terms as compared to plastics?
Polymers are the larger chemical group of large molecules consisting of repeating units, and plastics are polymers more specifically, synthetic polymers that may be shaped through heating. This difference in robotics assists engineers in choosing among the natural polymer options and engineered plastic materials according to the definite performance requirements.
Are CNC machined parts of plastics as strong as metal in robots?
For many applications, yes. The newer engineered plastics such as PEEK are able to compete or surpass certain metals in particular strength with considerable weight reductions. Nevertheless, metal parts might still be needed in extreme cases of load bearing or high temperature usage.
What is the reason why CNC machining is favored over molding of robotic parts?
CNC machining is better in low to medium production volumes, prototyping, and high tolerance, geometries of components. It enables the design to be altered without the costly tooling adjustments and may have accuracy that can be unattainable in molding.
Are polymer components safe in a human working robot?
Certainly, polymers employed in collaborative robotics are selected because of impact-absorbing characteristics and smooth surfaces, which are safer than their metal counterparts. Also, they do not carry electricity and the risk of electrical hazard is minimized.
What is the life span of polymer components in robots?
Lifespan is highly dependent on the nature of material, conditions of operation and application. There are those engineering polymers which can work over decades in the right conditions and there are those which are used as consumable components and have to be replaced periodically.
In which industries are polymer-based robotic components the most useful?
It has a major benefit in health care, food processing, electronic manufacture, and collaborative industry applications. The polymers are useful in these industries due to their cleanliness, corrosion resistance, light weight and safety properties.
Making Informed Material Choices for Robotic Applications
The knowledge around polymers and plastics and their use in CNC machined robotic parts is beneficial to any person seeking to know more about the modern manufacturing field. These materials have radically transformed the form of robots with lighter and more efficient machines and more specialized machines than ever.
The connection between material science and manufacturing methods will become increasingly significant as robotics keeps developing. You may be studying engineering, thinking about the career performance, or just interested in understanding how things are produced, but by understanding the strategic role of material selection you gain some idea about one of the most dynamic areas of manufacturing.
Future robotic systems are going to be even more exciting with the further evolution of new polymer materials and higher machining methods. Medical devices that will save lives and automation systems that will revolutionize transportation will be dominated by polymers and plastics that will be machined with accuracy until many years to come.
