PPS Is Too Brittle: How to Avoid Edge Chipping During Machining?

Yes. Acrylic is one of the few plastics that can achieve a mirror finish directly through cutting. We use single-crystal diamond tools for precision machining, followed by flame polishing or diamond grinding. Surface roughness is consistently controlled within Ra0.4μm, delivering a high-gloss appearance free of scratches or defects, resembling a mirror. No secondary coating is required. For batch production, identical parameters are used to ensure consistent mirror finish quality.

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Appearance quality is a core strength. We use a three-stage control process: during machining, sharp tools with high RPM and shallow cuts prevent tool marks and roughness; between processes, all parts are film-wrapped and transferred in individual stations to avoid stacking scratches; before shipping, each piece is inspected under standard light sources against strict criteria for glossy, scratch-free, and blemish-free finishes. Batch consistency is guaranteed by fixed parameters and fixtures, not manual picking.

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This is typically caused by excessive cutting heat. Acrylic has low thermal conductivity, so slow feed rates, high speeds, or dull tools cause chips to melt and stick to the tool, resulting in haze and stress-induced whitening. Our approach uses monocrystalline diamond tools with high RPM and small depths of cut, along with air cooling or minimal lubrication to dissipate heat. We leave a 0.05-0.1mm finishing allowance before final machining to prevent heat accumulation on already processed surfaces.

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The criteria for judgment are consistent: high gloss, high-shine surface, no scratches, and no defects. The difference lies in the process—aluminum parts rely on anodizing and polishing, while plastic parts use diamond cutting and flame polishing or mechanical polishing. When aluminum and plastic parts are mixed in the same batch, we standardize color swatches and gloss samples to avoid visual discrepancies between the two materials on the same product.

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PVC has poor thermal stability and decomposes to release hydrogen chloride when the cutting zone exceeds 150°C. The solution is to remove heat rather than force the cut: use sharp tooling, moderate spindle speeds, adequate air cooling or minimal oil mist lubrication, and ensure timely chip evacuation to prevent repeated friction from chip buildup. Our stations are equipped with independent exhaust systems, and parts are cleaned and packaged after machining.

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