Phenolic Machining
CNC Machining of Phenolic Composites
Canvas Phenolic ‘C’ • Canvas Electrical Phenolic ‘CE’ • Glass Phenolic ‘G3’ • Paper Phenolic ‘X, XX, & XXX’ • Natural Phenolic Electrical Grade ‘LE’ • Linen Phenolic ‘L’
Mayfly Manufacturing provides precision CNC machining of phenolic laminate composites for industrial and electrical applications where strength, wear resistance, and insulation matter.
Phenolics machine very differently than metals or plastics. Our processes are built to manage their brittleness, layered structure, and dust considerations—delivering clean features, controlled edges, and consistent results.
Why Phenolic Machining Requires the Right Approach
Phenolic laminates offer excellent mechanical and electrical properties, but improper machining can lead to:
- Edge chipping and breakout
- Layer separation
- Cracking at holes or sharp features
- Poor dimensional repeatability
- Excessive scrap
At Mayfly Manufacturing, we understand how phenolics behave under the cutter and adjust tooling, feeds, and fixturing accordingly.
Our Phenolic Machining Capabilities
We machine a wide range of phenolic laminate materials, including:
- Paper-based phenolics (X, XX, XXX) – Designed for electrical insulation in low-voltage applications.
- Cotton Fabric-Based Phenolics
- Canvas (C, CE) – Uses heavy cotton fabric for high impact strength and structural, gear, or pulley applications
- Linen (L, LE) – Uses a finer weave for precise, intricate machining of smaller components
- Glass-Reinforced Phenolics (G3) – Offer superior heat resistance, moisture resistance, and mechanical strength.
Typical Capabilities
- CNC milling and turning
- Precision drilling and countersinking
- Flat plates, spacers, blocks, and structural components
- Prototype through low–medium volume production
- Secondary operations as required
Typical tolerances of ±.005” are common, with tighter tolerances possible depending on material and geometry.
If your application requires durability, insulation, or wear resistance, we’ll help ensure the material and machining strategy are aligned with performance expectations.
What Sets Mayfly Manufacturing Apart
Composite-Focused Machining
Phenolics are not treated like metals in our shop. We use composite-specific tooling and strategies to minimize breakout and preserve part integrity.
Dust Control & Cleanliness
Phenolic dust management is critical for part quality, operator safety, and equipment longevity. Our shop practices are designed with composite materials in mind.
Engineering Support
We regularly work with engineers to:
- Adjust designs to reduce chipping
- Optimize tolerances for phenolic materials
- Improve manufacturability and yield
- Reduce cost without sacrificing performance
Reliable Production Partner
Purchasing teams rely on us for:
- Honest feedback on feasibility
- Predictable lead times
- Consistent quality
- Clear communication throughout the job
Common Applications for Machined Phenolic Parts
Phenolic composites are widely used in demanding environments, including:
- Electrical insulation components
- Wear plates and guides
- Structural spacers and blocks
- Industrial machinery components
- Legacy parts and replacements
If your application requires strength, insulation, and durability at a controlled cost, phenolic materials are often an excellent choice.
Design Tips for Machining Phenolics
Small design changes can significantly improve phenolic part quality and reduce cost:
- Avoid sharp internal corners when possible
- Allow generous edge distances for holes
- Specify tolerances only where functionally required
- Expect different tolerance behavior than metals
We’re happy to review your design and provide feedback before machining begins.
Request a Quote for Phenolic Machining
Looking for a CNC shop that understands how to machine phenolic composites correctly?
Upload your prints or models, and our team will review your requirements and follow up promptly.
