Custom Polystyrene (PS) CNC Machining Services | XML Precision Hardware Manufacturing

Searching for a cost-effective, highly rigid plastic with outstanding electrical insulation? XML provides expert Polystyrene (PS) CNC machining services. Valued for its brilliant dielectric strength, low moisture absorption, and excellent radiation resistance, Polystyrene is the perfect material for high-frequency RF insulators, medical laboratory trays, electronic housings, and rapid form-and-fit prototyping. From quick-turn prototypes to consistent volume production, XML delivers highly precise, all-around manufacturing solutions. Get a free quote today!

Why Choose Polystyrene (PS) for CNC Machining?

Polystyrene (PS) is a rigid, amorphous thermoplastic that is widely utilized across industrial and consumer sectors due to its incredibly cost-effective nature and unique physical properties. While it is more brittle than ABS or Polycarbonate, its performance in specific electrical and medical environments is outstanding.

Whether you are designing disposable medical equipment or testing an electronic enclosure, this material delivers:

Exceptional Electrical Insulation: Features an incredibly low dissipation factor and high dielectric strength, making it a highly sought-after material for high-frequency radio (RF) and radar applications.
Radiation Sterilization Compatibility: Highly resistant to gamma radiation without degrading, making it an industry standard for sterile medical diagnostics and laboratory equipment.
Cost-Effective Prototyping: Extremely affordable and highly machinable, providing an economical choice for rapid design validation, fit testing, and visual models.
Excellent Dimensional Stability: Low moisture absorption and a low coefficient of thermal expansion ensure that machined parts maintain their exact shape and tight tolerances.

As your expert manufacturing partner, XML utilizes specialized high-speed routing and low-pressure cutting strategies to machine this brittle plastic flawlessly, preventing any edge chipping or thermal cracking.

Polystyrene (PS) Technical Specifications & Machining Parameters

Mechanical & Thermal Properties	Metric Value	Imperial Value	Test Standard
Density (Specific Gravity)	1.04 – 1.05 g/cm³	0.038 lbs/in³	ASTM D792
Tensile Strength (Yield)	40 – 50 MPa	5,800 – 7,250 psi	ASTM D638
Flexural Modulus	2.8 – 3.2 GPa	400,000 – 465,000 psi	ASTM D790
Dielectric Strength	~ 20 kV/mm	~ 500 V/mil	ASTM D149
Water Absorption (24 hrs)	0.03% – 0.10% (Very Low)	0.03% – 0.10%	ASTM D570
Hardness (Rockwell M)	M70 – M80	M70 – M80	ASTM D785
Max Continuous Temp	70°C – 80°C	158°F – 176°F	UL 746B

Machining Parameters	Technical Specifications
Standard Tolerances	±0.05 mm to ±0.1 mm (Highly stable and accurate)
Minimum Wall Thickness	≥ 1.2 mm (0.047″) recommended to prevent vibration cracking
As-Machined Surface Finish	Ra 0.8 – Ra 1.6 μm (Smooth, bright finish achievable)
Cutting Strategy	High spindle speeds (12,000+ RPM) with highly controlled, moderate feed rates to minimize cutting pressure.
Tooling Specifics	Razor-sharp, single-flute solid carbide end mills with high clearance angles to slice the material without rubbing.
Coolant / Thermal Control	Cold air blast strongly recommended. PS is highly sensitive to chemical crazing caused by standard oil-based or alkaline coolants.
Post-Processing	Easily glued, chemically welded, or ultrasonically welded. Surface can be sanded and painted for cosmetic prototyping.
Supported Operations	3 & 4-Axis CNC Milling, Precision CNC Turning, Routing, Drilling (using specialized peck cycles to prevent breakout).

Extensive Industry Applications of ABS Parts

Aerospace

Offering outstanding dielectric properties, PS is ideal for high-frequency applications. We precision-machine custom RF insulators, radar radome prototypes, and lightweight electronic enclosures.

Medical Devices

Resistant to gamma radiation sterilization, PS ensures clinical safety. We manufacture highly precise medical laboratory trays, diagnostic test cassettes, and sterile packaging prototypes.

Robotics & Automation

Providing excellent electrical insulation and structural rigidity, PS protects sensitive systems. We CNC machine custom sensor housings, printed circuit board (PCB) covers, and high-voltage insulators.

Automotive

Highly cost-effective and rigid, PS is perfect for rapid form-and-fit testing. We machine automotive dashboard prototypes, custom display cases, and structural lighting housings.