Carville Ltd

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The Carville production facility has ISO9001 accreditation and over 80 years of experience in the heat treatment and CNC machining of acrylic and other engineering grade plastics.

Carville produce CNC machined component parts for medical, industrial and consumer applications. We operate schedule agreements to support customers with short lead-times and economic pricing.

Carville export 60% of all manufactured parts and supply to customers throughout Europe, Asia and the USA.
 

Plastic Machined Components

Plastic Machined Components
The Carville facility has ISO9001 accreditation and over 80 years of experience in the heat treatment and CNC machining of acrylic and other engineering grade plastics. Carville produce CNC machined component parts in a number of engineering grade plastics including:

  • PolyMethyl MethAcrylate (PMMA - Acrylic)
  • PolyCarbonate (PC)
  • PolyOxyMethylene (POM - Delrin)
  • PolyPropylene (PP)
  • PolySUlphone (PSU)
  • PolyEtherImide (PEI - Ultem)
  • PolyEther Ether Ketone (PEEK)
     

The above is not an extensive list. If you require a CNC machined component in an engineering grade plastic, please forward a manufacturing drawing to Carville for review.

 

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Plastic Machined Components

Acrylic Machining

Acrylic Machining

The Carville production facility is equipped with heat treatment ovens, CNC milling machines and CNC lathes. This compliment of CNC milling and turning machines allows Carville to offer our customers both conventional and diamond machining processes to achieve precision machined acrylic components and parts.

Carville produce a wide range precision CNC machined acrylic components for customers throughout Europe, Asia and the USA. Acrylic components parts include:

  • Perspex Acrylic Plastic manifolds for medical and industrial applications.
  • Perspex Acrylic Lenses and Light Guides
  • Perspex Acrylic Medical Quality Assurance Phantoms
  • Acrylic Fine Writing Instruments
  • Acrylic component parts for use in medical and industrial applications
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Acrylic Machining

Acrylic Light Guides and Lenses

Acrylic is half the weight of glass, has excellent optical clarity and light transmission properties. Acrylic is ideally suited to the manufacture of acrylic light guides and lenses.

Carville produce CNC machined acrylic light guides and lens components for use in the automotive, aerospace, medical and industrial sectors.

Light guides can be simple components such as a round acrylic light pipe or may be more complex components which have been fabricated, formed and wrapped to guide a light source to a particular receiving area within a larger assembly.
 

Acrylic Light Guides and Lenses

Quality Assurance Phantoms

Success within the Radiology and Oncology market can be linked to the advances in clinical screening techniques such as X Ray, CT and MRI Scanning. These diagnostic machines assist medical professionals in the identification and treatment of life threatening medical conditions.

It is essential to the medical profession that equipment can be calibrated in a reliable and repeatable way. Calibration of equipment requires the use of Quality Assurance Phantoms which either simulate human tissue or assist in equipment set-up.

Carville produce a range of phantoms in acrylic and other engineering grade plastics which are used to calibrate both static and mobile screening and treatment systems.
 

Quality Assurance Phantoms

Fine Writing

Due to its light weight, balance, warm feel and attractive cosmetic appearance, acrylic is a very popular material in the production of component bodies for the fine writing instrument market.

Using Diffusion Bonding and casting techniques that were originally developed to support the aerospace and medical markets, Carville produce precision machined components parts for some of the world’s leading writing instrument manufacturers.

These acrylic pen components are used as bodies for high end fountain pens, roller balls, ball pens and pencils. Materials may be machined, bonded and cast to create unique patterns that are supplied on a exclusivity basis, are long lasting and hard wearing.
 

Fine Writing

Semi Conductor

Carville CNC machines a range of precision machined component parts for use in the semi-conductor manufacturing industry. It is critical to the wafer manufacturing process that components such as thrust plates are produced to strict tolerances with regards both machined dimensions and surface flatness.

Semi Conductor

Aerospace Components

Carville has a long history of producing precision machined component parts for use in the aerospace industry. As weight is an important consideration, many of these components are precision machined in either engineering grade plastics or aluminium.

Aerospace Components

Heat Treatment of Plastics

The most cost effective way to produce materials such as Acrylic is to use either a casting or extrusion process. Although cost effective, cast acrylic or extruded acrylic materials can be highly stressed and may distort during the manufacturing processes.

To ensure stable dimensions and a long life for precision machined component parts, it is essential that materials are correctly heat treated to remove internal stress. Carville will not manufacture plastic component parts without fully heat treating the base material at the pre-production stage.

On materials such as acrylic (PMMA), these initial heat treatment processes can result in material shrinkage of between 2% and 4%.

All plastic materials used by Carville are normalised using controlled heat treatment processes before any machining operations take place.

During the production process, all components are stage annealed to remove any stresses that may have been induced due to the machining processes.
 

Bonding of Plastics

Carville use four principal methods of bonding Acrylic and other plastics:

Diffusion Bonding
The diffusion bonding process allows plastic materials to be joined without the use of solvents or adhesives. The material is joined at a molecular level which ensures that any thermal expansion or contraction of the material will not have a detrimental effect.

HAB Bonding
As the fluidic application demands within the medical sector have increased, chemistries have become more aggressive and sample sizes have reduced. These changes have resulted in a demand for smaller micro fluidic style devices that can be produced in alternative engineering grade materials.

Carville have worked with clinical diagnostic companies on the development of this new HAB manufacturing technique and supply finished component parts to customers in UK, Europe, Asia and the USA.

Plastic Cementing
Polymerising cements can be used to produce strong, optically clear joints that are cosmetically attractive. It is important that plastics joined with polymerising cements are suitably heat treated to remove internal material stress. Failure to heat treat may result in solvent induced stress crazing or cracking of the material.

Solvent Cementing
This is a low cost method with a limited number of applications. Plastic materials may be joined by applying a suitable solvent and then clamping the materials together. It is imperative that the materials to be joined are correctly heat-treated. Failure to heat treat may result in solvent induced stress crazing or cracking of the material.
 

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