Guide to Choosing the Right Plastic Extrusion Machine for Your Business

Fiber laser cutting has become the gold standard of manufacturing since it is able to create intricate designs with utmost precision in a high volume. This manufacturing technique has been adopted by nearly every type of industry. However, it is a difficult technique to master, and many times, the finished product does not have a refined shape. While the fiber laser is an amazing piece of technology, getting the best result from it requires handling it correctly. In this blog, we will tell you exactly how to achieve a perfectly cut product through a fiber laser by telling you about the most common mistakes that occur during the laser cutting process and how to avoid them. Roughness Rough and irregular edges are one of the five laser-cutting mistakes that gives the product an unappealing and unfinished look. This is usually observed in vertical lines. The kind of the cutting section's roughness depends on the depth of the material that is being cut. It follows that if the texture is thin, then the cutting line will have a smooth appearance. Obviously, the roughness is caused by friction encountered by the laser. In most cases, therefore, it would be desirable to decrease the roughness to attain a higher quality of cutting. Carbon steel is a material that results in rough cutting since the steel plate has a thickness that makes cutting difficult. As a result, the laser power of the fiber laser cutting machine should be altered with changing thickness. Generally speaking, a 1000W fiber laser source can do a nice and clean cut on carbon steel no more than 4mm, 2000W is 6mm, and 3000W is 8mm. Burr Formation Burrs visually appear as raised edges and create an uneven surface. This gives the product an unrefined appearance. Burr formation takes place due to multiple factors. As a manufacturer, you need to be extra careful to remove the dross. How do we prevent dross in laser cutting? Make the necessary adjustments to improve laser focus and beam quality The laser position, power, and feed rate should be altered to make a clear cut. Air pressure should be kept uniform and at the correct value for the removal of the molten deposit. Material Discoloration Burnt appearance of the material usually results from oxidation that takes place on the cutting edge of the laser and this causes color changes on the surface which affects the visual appearance of the product making it look cheap. How to prevent discoloration in laser cutting? Cutting parameters such as laser focus, power, and speed should be adjusted to reduce heat generation during cutting. Use assist gas with appropriate composition and flow rate to protect the material from oxidation during laser cutting. The laser power supply provides the necessary laser power, while the laser tube emits a focused beam of light for precise cutting. This ensures a laser focus on the material and enhances the overall cutting quality. Treat the cut surfaces with appropriate post-cut treatments, like passivation or surface coating, to restore their original appearance and prevent further oxidation. Gas Pressure Fluctuations Grass pressure that is not constant results in irregularities in cut quality by creating a tapered edge. This gives cut object an uneven appearance. How can pressure fluctuations in laser cutting be prevented? Only use a laser cutting machine that has a precise gas pressure control mechanism. Recalibrate the gas pressure control system to ensure an accurate function. Cutting conditions should remain constant during cutting, and this can be done by carefully monitoring and altering gas pressure. Warping of Thin Material When it comes to cutting a thin material, the user needs to be extra careful since the laser's intensity can cause warping of the material due to the heat generated. How to prevent warping in laser cutting? Minimize warping chances by utilizing a laser with a high-frequency pulse that reduces heat input. Securely fix the material in a place by utilizing adequate clamping material to stabilize shifting of the material during the cutting procedure. This improves a the focus of the laser. Make use of a cooling system or heat sink to keep the material at a constant temperature while performing the cutting. Moreover laser focus should remain stable and precise for the best results. Conclusion Metal laser cutting has proven to be very versatile manufacturing with high-speed cutting for parts that may find usage in a wide variety of applications. Precautions for common defects associated with laser metal cutting are held paramount as the quality of cuts should be ensured. By prevention methods, you will be improving on your general performance of cutting, and you will finally achieve optimum results.

Extruded plastics are widely utilized across various industries, with demand expected to increase at a CAGR of 4.5% from 2020 to 2027. This expansion is driven by the growing need for efficient, reliable, and more sustainable reusable components. Additionally, the market for plastic extrusion machines is anticipated to experience a 6.9% growth due to rising buyer demand globally over the forecast period. There is a large variety of plastic extrusion machines available in the market and choosing one that fits the requirements means that you need to be well-acquainted with the features of the machines as well as your own requirements for output. In this blog we will tell all you need to know regarding extrusion machine features and their compatibility with your raw material so that as a buyer you make the correct selection. Selecting The Right Extrusion Machine: What Features to Consider Screw Diameter, Design, and Speed When it comes to determining machinery output, the screw of the extruder machine is instrumental. Screw performance is the main factor that determines productivity, quality of finishing, mixing of additives, melt temperature, and power consumption. The screw is the most important component of an extruder machine. Screw rotation is responsible for exerting pressure on the plastic. The screw diameter determines the output and is also responsible for shearing plastic, so selecting a machine with the right screw diameter is crucial for high output and quality products. Screw speed is another aspect that determines the production output. But a high speed can twist and break the screw; however, this can be offset with a well-designed screw shape. Barrel Structure Sensors Extrusion efficiency is also determined by the barrel structure component of the extrusion machine. The barrel structure’s main role is to regulate the temperature of the feeding section. The barrel structure consists of a water jacket, and a high temperature of the water jacket means the raw material will soften prematurely, which will reduce extrusion thrust and volume. On the other hand, if the temperature is too low will increase screw resistance which will make rotation speed unstable. So, to ensure a suitable temperature in the barrel structure, the extrusion machine should have built-in advanced temperature sensors to ensure the extrusion process characteristics. Motor Drive and Power Consumption Power efficiency of an extruder is vital aspect of operating costs and it is always better to  opt for energy efficient extruders. Motor drive and transmission is the component that consumes the  most electaricity approximately 77% while heating and cooling accounts for the remainder of the energy consumption. Shock Absorption Components Extrusion machines produce a lot of vibration, and high vibration reduces the usage life of parts and increases the risk of a breakdown. So, always choose an extrusion model that has a low vibration and is fitted with shock-absorbing components. The extrusion machine should be fitted with a low-vibration motor. Additionally, the extrusion machine should have a rigid and sturdy frame that absorbs the vibration. A frame that has a robust build and sufficient weight can absorb the vibration. The extrusion machine is not supposed to be fixed with bolts for stability during operation. Intuitive Controls and Display Panels A top-quality extrusion machine should be easy to operate and the feature that helps the most I easy operation are well-defined button layout and panels and meters with clear displays that communicate relevant information about the extrusion process happening inside the machine. Hence, once you start your buyer search for an extrusion machine, focus on shortlisting only those machine brands that have intuitive controls and adequate display panels that make machine operation easy to control. Intuitive control can enhance the precision of an extrusion process. Pricing and Budget Considerations Investing in fixed machinery is always going to way heavy on the pocket and that is why you need to consider your expected ROI and balance it with the machine capabilities, price and features. A crucial aspect that many manufacturers neglect in buying decision is after purchase expenses like maintenance cost, parts replacement and energy consumption. These expenses have a negative impact in the long-term profitability. Brand Reputation and Technical Support Last but not the least machine brand carries a lot of Importance during purchase of extrusion machine. A reputed brand will not only have an extensive lineup which gives you plenty of options to choose a machine that matches your production capacity requirements. But also gives you warranty and technical support which is really important in long term. Conclusion Choosing to invest in a plastic extrusion machine is a crucial decision that can greatly influence your production capabilities and drive business growth. By carefully evaluating these essential factors, you can choose a machine that aligns with your production requirements while delivering efficiency, quality, and dependability. Keep in mind that the right machine is a valuable asset that can optimize your manufacturing process and play a pivotal role in the success of your business.

Professionals and hobbyists around the world know the struggle of maintaining CNC machines. They have to keep every component in good condition to avoid problems with these machines. Yet, they face some common issues, whose solutions are possible. Some of them are in this blog, and you can learn how to deal with them. Machine is Overheating  Many users notice this issue in CNC machines whether it is for wood machining or any general one. Overheating is a problem that indicates that there is an internal issue like friction or obstruction. That increases the temperature of the machine more than the usual one.   Solution The solution for that is the inspection of internal components regarding the friction level. If there is too much heat generation, that means there is friction inside it. You will have to lubricate the moving components to reduce the heat.  Also, inspect the cooling fan whose primary function is to cool down the machine. That fan must be underperforming or having problems.  You need to inspect the coolant’s level in the tray. Make sure the coolant is in good condition as well as in limit. Inaccurate Machining The machining quality is dropping and the inaccuracy level is increasing. That is another problem users experience. That could be a problem with the software and its alignment. When there is an issue with the coding and a lack of updates, these issues arise.  Solution There might be the insertion of the wrong code, which is creating confusion for the machine. Due to this problem, a machine fails to operate properly. As a result, the inaccuracy in production increases.   This could be a problem regarding the selection of G codes and M codes. When you use wrong codes, which are not compatible with the machining technique, this could cause inaccuracy. Alignment of working tools and tooling paths is also mandatory. Without this alignment with the software, one can not expect accuracy in final results on wooden objects. Speed Issue or Tools Not Moving at All Machining tools sometimes cause too much vibration or get jammed. That could be because of an internal issue that leads to jamming. You need to inspect the reason behind it because it can also affect the speed of tools.  Solution Since it is related to the movement of tools, the spindle motor might be having issues. If the tools are not moving at all, that means the spindle motor is jammed because of a technical issue.  There could also be an insufficient current coming from the electric supply. Since an electric supply is the main source of running spindle motors, you will have to inspect both of them. That will let you know where the problem lies.  There could also be a problem with the bearings in the spindle motor. Either they have worn out or damaged, which leads to poor performance of the spindle motor.   The last possible issue could be a problem with the control card. That is disconnecting the tools from the computer system. It is not receiving the signals from the computer to act accordingly.  Hard Noises in the CNC Machine If your CNC machine is causing hard noises in the operation, that could be a problem with the internal components. That might be loose connections between components. When it happens, your machine will face vibrations as well as hard sounds.   Solution What you need to do is inspect any loose parts installed in your machine. That loose part is causing noise and vibration, which is affecting the performance. Tighten them to ensure there is no such sound after that. Another reason is friction between the parts because of a lack of lubrication. You will have to do some oiling and greasing to reduce the friction for smooth performance.  Your spindle motor might need inspection or replacement if it is the cause of the noises. When the spindle motor reaches its end, it creates problems like that.  Tools are Not Acting on the Given Instruction Sometimes your CNC machine’s tools do not act according to the given instructions. Either one or all the axes do not move in the right direction. That shows a poor connection between the computer and the servo motor. There is a possibility that the X, Y, and Z axes are giving incorrect responses. Solution   You will have to inspect the connection between the computer and the card. That might be the failure in the card, which is not letting the signals reach the servo motor. The only way to make all axes work in the right way is to replace the card. Having Burn Marks on Wood Pieces The last common problem that occurs when using a wood CNC machine is burn marks. People often notice this issue in the final outcome of wood pieces. Solution  The only way to avoid those burn marks is by using sharp tools with high depth. If the tools are not sharp, they will need more time. That time of machining will increase the risk of burn marks. What you need to do is reduce the machining time to reduce the risk of burn marks.  Conclusion Maintaining a wood CNC machine requires vigilance and regular inspections to prevent common problems like overheating, inaccurate machining, tool jamming, noise issues, improper tool movement, and burn marks on wood pieces. Each issue has specific causes and solutions, often involving checks on internal components, software alignment, and proper lubrication. Regular maintenance and timely troubleshooting can significantly extend the life of the CNC machine and improve its performance. By understanding these common issues and implementing the suggested solutions, users can ensure smoother operations and better quality results in their woodworking projects. Remember, proactive maintenance is key to keeping your CNC machine running efficiently.