Machining Tools

The right tool for the best finish: a quick tool guide for machining HYTAC syntactic foam.

HYTAC syntactic foams are best machined using sharp solid carbide tools specifically designed to cut abrasive plastics. Following recommended guidelines for chip load and depth of cut will provide excellent finish results and long tool life.

Recommended tools, available directly from CMT or your current tool supplier, are shown below. A wide variety of optional tools and coatings for even longer tool life may be available upon request.

Tools for Milling of HYTAC and Protoblock

  • Double Flute Upcut Spiral End Mill – High helix geometry, solid carbide, designed to cut with a smooth finish and upward chip flow for rapid material removal, slotting and profiling. Special point geometry for excellent bottom finish. Conventional milling is recommended. See HYTAC Machining Guide for complete feed and speed recommendations.
  • High Finish Ball Nose – For contouring of HYTAC and Protoblock materials, CMT offers a solid carbide ball nose design with a uniquely designed point and highly polished primary clearance and flute to eliminate the tool marks typically associated with plastic machining. Conventional milling direction is recommended. See HYTAC Machining Guide for complete feed and speed recommendations.
  • Tapered Ball Nose – Solid carbide tools available with a variety of taper angles. Optimized geometry produces a good edge finish in HYTAC or Protoblock materials. Conventional milling direction is recommended. See HYTAC Machining Guide for complete feed and speed recommendations.

Tools for Milling of METAPOR®

  • Two Flute Aluminum Cutting Tools – Open flute geometry is optimized for slotting and profiling of METAPOR porous tooling materials. Climb milling direction is recommended. See METAPOR Machining Guide for complete feed and speed recommendations.
  • Two Flute Aluminum Ball Nose Cutting Tools – Polished flutes with optimized geometry for 3D contouring provide a smooth finish, long tool life and maximized productivity. See METAPOR Machining Guide for complete feed and speed recommendations.