Considerations when Designing Large CNC Routed Plastic Components

When it comes to manufacturing large-scale components, CNC routing of plastics presents a cost-effective and versatile solution. Gemini Plastics, Inc., with over 50 years of expertise and a digital-first, service-driven mindset, offers robust capabilities in CNC plastic routing—making us the right manufacturing partner for your precision-driven projects. Let’s dive into the top considerations to keep in mind when designing large CNC‑routed plastic components:

1. Know Your Size Boundaries and Tolerances

Our CNC routing capabilities cover parts up to 324 in length and 61" width, handling materials up to 3" thick with tight tolerances of ±0.015".

2. Select Materials Based on Function

Gemini Plastics offers a wide range of industrial-grade materials suited for varied applications—including ABS, Nylon, Glass-Filled Nylon, Polycarbonate, HDPE, UHMWPE, PEEK, Ultem, and more.

Key Factors to Evaluate:

• Mechanical Stress & Wear: Use Glass‑Filled Nylon or UHMWPE for high abrasion resistance.

• Chemical or Thermal Needs: Acetal and PEEK excel in chemical resistance; Celazole or Ultem suit high-temperature environments.

• Aesthetic or Clarity Needs: ABS excels in appearance; Polycarbonate and PETG offer transparency.

3. Ensure Designing for Precise Machining

Gemini's state-of-the-art CNC systems—equipped with 3-axis machines, CAM programming, and automatic tool changers—deliver repeatable precision across complex geometries.

Best Practices:

• Avoid overly thin sections which can flex or deflect.

• Incorporate proper tapers and radii for smooth tool engagement.

• Design parts with ideal stock allowances, taking into account rigid clamping and part stability.

4. Leverage Design Support & File Compatibility

Gemini collaborates with CADmore, offering design and engineering support that helps bridge the gap between napkin sketches and manufacturable CAD files. CADmore supports file formats including STEP, SLDPRT, STL, IG, DXF, DWG, PDF, and ZIP.

Benefit: If your design isn't production-ready—or if you have only a rough concept—Gemini and CADmore can assist with scanning, optimizing, and converting files to create a smooth path to fabrication.

5. Understand Lead Times & Turnaround Options

Standard turnaround is 2–3 weeks, with rush options available when time is critical.

Curtailing Delays:

• Provide finalized designs and material specifications early.

• Submit clear part volume forecasts—especially if scaling from prototype to production.

6. Emphasize Quality and Standards Compliance

As an ISO 9001:2015 registered facility, we ensure tight quality controls and a commitment to continuous improvement.

Designing for Quality:

• Provide explicit tolerance callouts.

• Include GD&T only where needed—but don’t over-constrain.

7. Scale with Integrated, Value-Added Services

Beyond routing, Gemini provides in-house tooling, vacuum forming, injection molding, hot stamping, and assembly services—all under one roof. This integrated manufacturing ecosystem streamlines workflow and ensures accountability across all stages—from CAD to final delivery.

Quick Recap

Consideration	Design Insight
Size & Tolerances	Stay within 324″×61″×3″; ±0.015″ achievable
Material Selection	Match properties (wear, chemical, aesthetic) to material choices
Machinability	Avoid deflection, build in tool path logic
Design Support	Use CADmore + file compatibility to refine designs
Lead Time Planning	Standard: 2–3 weeks; rush options available
Quality Standards	Produced according to ISO 9001:2015 Standards

Why Choose Gemini Plastics for Large CNC-Routed Parts?

With 50+ years of experience, Gemini Plastics blends industry-leading technology with a dedication to service. Offering seamless quoting, CADmore-backed design partnerships, and a powerful suite of machining and post-processing capabilities—all housed in an ISO 9001:2015 environment—Gemini enables your vision, from concept to completion.

Final Thoughts

Designing large CNC-routed plastic components requires strategic planning around size, material, manufacturability, and logistics. By collaborating with a partner like Gemini Plastics, you gain access to both expertise and infrastructure that can translate complex, high-precision designs into production-ready reality. Need help fine-tuning your design—or want to explore optimal materials or tooling strategies? Let me know, and I’ll be glad to help—or you can Request a Quote directly via Gemini’s website.