HDPE, or High-Density Polyethylene is a sort of a super-material of the modern day maker. It does not matter whether you are creating marine grade parts or you are creating your own jigs; the next step is to find a supplier of reliable HDPE. The magic is in the actual realisation when you carry it to your work bench.
Although it is as easy to work with as timber, HDPE has distinct thermal characteristics which demand a certain strategy. This is the way to become a master in machining this all-purpose plastic in your own Australian home workshop.
How to make Your Shop HDPE a Success
Unlike timber, HDPE is not splintered, but may melt when your tools cause excessive friction. Always when you shop HDPE sheets, it is important to have a flat stable piece of work so that this material cannot vibrate and cause chatter marks to the final edge.
The Choice of a Tool: It is all about being sharp
Carbide-tipped tools are the golden rule to machining HDPE. Regular HSS high-speed steel bits may be quickly dulled and produce a lot of heat.
Saw Blades: circular saw: 60-80 teeth
Routers: Riners prefer single or double fluted bits to permit quick clearance of chips.
Professional Methods of Cutting and Routing
Managing Heat and Speed
When the plastic beads or melts behind your blade, then you are feeding too slow or you have too high an RPM. You have got to make clean shavings, not dust and molten blobs.
Drilling and Fastening
During drilling, a normal twist bit is used though back-out is frequently used to remove swarf. Since the HDPE is a high thermal expansion material, it is prudent to bore holes in the material a bit bigger than your screw so that the material can get to breathe in the hot South Australian summer.
Finishing Your HDPE Project
The advantages of this material include the fact that it does not need paint or stain. After machine work, the edges may be softened with:
A De-burring Tool: Ideal in edge cleaning.
Sandpaper: Use 120 grit initially then proceed with 320 in order to get a matte finish.
A Heat Gun: A quick stroke can give a freshly sanded edge a new shine, however, do not over do it.
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Summary
It is so rewarding to master HDPE at home. It is hardy, rot resistant and very professional in outlook. With this combination of shopping HDPE next time you need it, and this combination of cooling and cutting methods, you will end up with industrial quality results with just ordinary woodworking tools.