Aerospace systems, electrical components and other industries all deal with intense heat. Components must be able to handle extreme conditions without damage. When failure isn’t an option, manufacturers turn to phenolic materials for their strength, heat resistance and insulating properties.
Phenolic components are essential for ensuring high-performance materials can withstand demanding applications. From switch panels to high-voltage insulators, phenolics are trusted for their reliability and stability across industries.
Phenolic materials are composites designed for durability. Manufacturers combine phenolic resins with base layers like linen, paper, canvas or glass. Then, these combined materials are cured under heat and pressure. The result is dense, strong sheets that can be used for high-performance applications.
What makes phenolics unique is their thermosetting nature. Once hardened, they won’t soften again. That means phenolics are extremely dimensionally stable, even under thermal or mechanical stress. A piece of paper on its own is flimsy and bendable, but coat it with phenolic resin and treat it, and it becomes durable and excellent for electrical insulation. Phenolics are the largest class of thermoset materials, with a wide range of materials underneath the umbrella.
Phenolics stand out thanks to their:
The material you combine with phenolic resin influences its performance and application. Here’s how the reinforcement material affects your choice:
Terms like LE, G10 and CE are all designations for laminates from the National Electrical Manufacturers Association (NEMA). NEMA designates a grade for laminates that incorporate resin systems, including phenolics. The grades act as a shorthand way to refer to the material. Each different grade has specific uses and special characteristics.
Phenolics are durable, but that means they need proper machining techniques to ensure quality results. Phenolics respond well to standard machining techniques like sawing, milling, turning and drilling — with the right technique. The key is working with a partner who can tailor tooling and parameters to the grade and reinforcement material.
Tool selection makes all the difference in the end result. High-speed steel (HSS) tools work well for small jobs and softer grades like paper-reinforced phenolics. If you’re working with tougher materials like G10 or FR4, you’ll want to use carbide-tipped tools. These will hold their edge longer and reduce chipping in tougher pieces. Tools must be sharp to avoid fraying and improve accuracy.
Phenolics aren’t pure metals. Adjust speeds and feeds based on the grade. Carbide tools can run faster than HSS, depending on the parts you’re working with. The right speed and speed will limit overheating and delamination. Too fast, too slow or improper feeding will damage the material and lead to quality concerns.
Phenolics are usually dry-machined. Adding liquid coolant can cause swelling or warping. Compressed air cooling blows away dust and prevents overheating during machining. It’s much cleaner than liquid methods and minimizes tolerance issues.
Drilling phenolic materials means balancing speed, clearance and drill material. High-speed drills need proper clearance to prevent binding and chip buildup. Use carbide-tipped drills for longer holes or glass-reinforced grades. Make sure workers regularly lift the drill to clear chips and back up the material to avoid breakout.
If you’re going to create threaded holes in a piece, you should use a slightly oversized tool. Phenolic materials don’t deform like metal. Standard tap sizes can lead to tight, brittle threads. Going slightly oversized opens up the material enough to make it usable. Additionally, you can use metal inserts in repeat-used threads to add strength and durability.
Phenolic parts are used across dozens of industries. Their heat resistance, strength and electrical insulation make them highly versatile. Here’s how they’re used in manufacturing:
Phenolic machinery offers unmatched versatility and performance for your more demanding applications. With excellent mechanical strength, electrical insulation, and heat and chemical resistance, phenolic materials can handle your high-performance needs. But you need more than just phenolic material. You need a partner that understands machining phenolics, what tools to use and how to fit the parts to your operation.
At American Micro Industries, we specialize in machining hard-to-find, made-to-order parts from phenolic materials. Whatever your industry, we can help. Our decades of experience, in-house capabilities and commitment to quality give you unmatched results.
If you need a custom phenolic component delivered fast and machined to spec, choose American Micro Industries. Contact us today to request a free quote. Let’s build something that performs under pressure.
