Custom Machined Bushings
A bushing is one of the most tolerance-sensitive machined parts in any assembly — the bore must fit the shaft, the OD must press into the housing, and both fits must be held production-to-production. Federal Materials machines plastic and thermoset bushings to customer prints, holding bore tolerances to ±0.0005" on critical dimensions and concentricity to 0.001" TIR as standard.
We machine bushings in the full range of engineering plastics: self-lubricating grades (Torlon 4301, Delrin AF, PTFE-filled PEEK, carbon-filled PTFE) for dry-run applications; fiberglass-reinforced laminates (G10, FR4) for insulating bushings in switchgear; and high-temperature grades (Vespel, Torlon) for elevated-temperature service. Whether you need one prototype bushing or ten thousand production pieces, we quote and machine to your print.
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Request a Quote →Bushing Types We Machine
- Plain cylindrical bushings — close-tolerance ID/OD, press-fit or slip-fit in housing
- Flanged bushings — OD flange for axial retention; any flange OD and thickness
- Thrust bushings — combined radial/axial bearing function
- Self-lubricating bushings — Torlon 4301, Delrin AF, PTFE — for dry-run and low-maintenance assemblies
- Insulating bushings — G10, FR4, phenolic — for electrical isolation at bolt and shaft pass-throughs
- High-temperature bushings — PEEK, Torlon, Vespel — for elevated-temperature rotating and reciprocating service
- Stepped bushings — OD or ID step for compound fits
- Split bushings — axially slotted for installation into blind housings
- Long sleeve bushings — high L/D ratio, for guide and sliding-contact applications
Material Selection Guide
| Material | Max service temp | Key advantage | Best for |
|---|---|---|---|
| Delrin (acetal) | 220°F | Economical, stiff, self-lubricating | Light-duty mechanical |
| Delrin AF | 220°F | PTFE-filled, lowest friction | Low-speed dry-run |
| PTFE | 500°F | Chemical resistance, ultra-low friction | Chemical service, slow speed |
| PEEK | 480°F | High load, high temp, chemical-resistant | Process equipment |
| PEEK carbon-filled | 480°F | Best wear rate of any PEEK | High-duty cycles |
| Torlon 4301 | 500°F | Highest PV of any unfilled plastic | Hot dry-run, heavy load |
| G10 / FR4 | 285°F | Electrical insulation, structural | Switchgear, electrical assemblies |
| Phenolic CE | 220°F | Economical, electrical-grade | Motor and transformer bushings |
| Vespel SP-21 | 550°F | Extreme temp + self-lubricating | Aerospace, vacuum |
Typical Tolerances
| Dimension type | Production tolerance |
|---|---|
| Bore ID (critical fit) | ±0.0005" |
| OD (press-fit) | ±0.0005" |
| OD (slip-fit) | ±0.001" |
| Length | ±0.005" standard; ±0.001" on request |
| Concentricity (ID to OD) | 0.001" TIR |
| Surface finish (bore) | 63 µin Ra standard; 32 µin on request |
Fit class (H7/p6, H7/f7, etc.) can be specified on your print or RFQ. We will confirm machinability for any tolerance tighter than those above at time of quoting.
Finish Options
| Finish | Description |
|---|---|
| As-machined | Standard for all thermoplastic bushings — smooth, deburred, bore finish to spec |
| Honed bore | Bore honed to 32 µin Ra or better for precision bearing fits |
| Hot oil dip | Standard for phenolic bushings — seals and protects cut surfaces |
| No plating | Plastic bushings do not require metallic surface treatment |
Standard Turnaround
| Stage | Lead time |
|---|---|
| Quote response | Same business day |
| Prototype / first article (1–10 pcs) | 3–5 business days |
| Short run (10–100 pcs) | 5–10 business days |
| Production run (100+ pcs) | 10–15 business days |
Bushings are lathe-turned in batches — setup cost amortizes quickly, making production pricing competitive at moderate quantities.
Materials We Stock (Bushing Stock Shapes)
| Material | Stock form | Sizes |
|---|---|---|
| Delrin 150 | Rod | ¼" – 10" diameter |
| Delrin AF (PTFE-filled) | Rod | ¼" – 4" diameter |
| PTFE virgin | Rod | ¼" – 12" diameter |
| PEEK unfilled | Rod | ¼" – 6" diameter |
| PEEK carbon-filled | Rod | ¼" – 4" diameter |
| Torlon 4203 | Rod | ½" – 6" diameter |
| Torlon 4301 | Rod | ½" – 4" diameter |
| G10 | Rod, tube | ¼" – 6" diameter rod; tube sizes vary |
| CE Phenolic | Rod, tube | ¼" – 6" diameter rod |
| Vespel SP-1 / SP-21 | Rod | ¼" – 4" diameter |
Quality & Inspection
- 100% dimensional inspection — bore, OD, length, concentricity on all production orders
- CMM first-article — bore, OD, runout, surface finish measurement; report provided on request
- Fit verification — go/no-go gauge inspection for critical fit classes
- Material certification — grade, lot, and specification traceability with each order
- Visual and surface inspection — no voids, inclusions, or machining marks in bore
Get a quote on
Request a Quote →More Related Guides
- Custom Machined Standoffs — threaded cylindrical parts
- Vespel Machined Parts — extreme-temp bushing grade
- Teflon Machined Parts — PTFE bushings
- CNC Turning Thermoset Rod — turning process overview