Custom Machined Plastic & Thermoset Parts
Federal Materials machines precision plastic and thermoset parts to customer prints — from single prototypes to production runs of thousands. Our CNC turning and milling cells are dedicated to insulating and engineering plastics, with tooling, fixturing, and dust-management systems configured for the specific cutting characteristics of fiberglass laminates, phenolics, and high-performance thermoplastics.
We machine in all the materials that matter for electrical, switchgear, and industrial applications: G10, FR4, phenolic (XX, CE, LE), GPO-3, PEEK, Vespel, Torlon, Delrin, and PTFE. Every order ships with material certification; dielectric testing is available on request.
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Request a Quote →Browse by Material
These pages cover what we machine in each material, typical tolerances, finish options, and available stock shapes.
| Material | Page |
|---|---|
| G10 Fiberglass | G10 Machined Parts |
| FR4 Fiberglass (UL94 V-0) | FR4 Machined Parts |
| CE Canvas Phenolic (Electrical) | CE Phenolic Machined Parts |
| XX Paper Phenolic | XX Phenolic Machined Parts |
| All Phenolic Grades | Phenolic Machined Parts |
| PEEK | PEEK Machined Parts |
| Vespel (Polyimide) | Vespel Machined Parts |
| Torlon (PAI) | Torlon Machined Parts |
| Delrin (Acetal Homopolymer) | Machined Delrin Parts |
| Teflon / PTFE | Teflon Machined Parts |
Browse by Part Type
These pages cover a specific part geometry across all applicable materials.
| Part type | Page |
|---|---|
| Electrical insulators | Custom Machined Insulators |
| Washers & thrust washers | Custom Machined Washers |
| Bushings & sleeves | Custom Machined Bushings |
| Standoffs & spacers | Custom Machined Standoffs |
| Arc chutes & arc barriers | Machined Arc Chutes |
Browse by Process
These pages explain our machining process for each blank type — useful when you are choosing how to machine your part.
| Process | Page |
|---|---|
| CNC turning thermoset rod | CNC Turning Thermoset Rod |
| CNC milling thermoset sheet | CNC Milling Thermoset Sheet |
Our Machining Capabilities at a Glance
| Capability | Detail |
|---|---|
| Materials | G10, FR4, CE, XX, LE, GPO-3, PEEK, Vespel, Torlon, Delrin, PTFE, and more |
| Processes | CNC turning, CNC milling, drilling, tapping, boring, threading, routing |
| Critical tolerance | ±0.0005" on turned OD/ID (fiberglass and high-performance grades) |
| General tolerance | ±0.005" standard |
| Thread classes | 2B/3B per print; UNC, UNF, metric |
| Finish options | As-machined, hot oil dip (phenolic), face-ground, honed bore |
| Dielectric testing | Hipot, megohm, dielectric withstand — available on request |
| Quality documentation | CMM first-article, material C of C, lot traceability |
| Minimum order | No minimum — prototype to production |
| Quote turnaround | Same business day (standard RFQs) |
Why Material Choices Matter Here
Not all dielectric plastics are the same, and substituting one for another without engineering review can affect the performance and listing of your assembly:
- G10 ≠ FR4. FR4 carries a UL94 V-0 flame retardant; G10 does not. For UL-listed switchgear, FR4 is required. For non-UL applications, G10 is an equivalent structural-dielectric choice.
- XX Phenolic vs. CE Phenolic. XX (paper base) is more economical; CE (canvas base) has better impact resistance. Both are phenolic, but the filler affects mechanical behavior and surface finish.
- PEEK vs. Vespel. PEEK machines faster and costs less; Vespel handles higher sustained temperatures and hard vacuum. For most applications below 480°F, PEEK is the right call. Above that, Vespel or Torlon.
- Delrin vs. acetal copolymer. Delrin (homopolymer) has slightly higher stiffness and hardness; copolymer has better chemical resistance to alkalis and weld lines. Both are excellent machining materials.
Include your application requirements in your RFQ — our application engineers will confirm the right material before we cut.
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