ROHACELL® Machinability
ROHACELL® is a closed-cell polymethacrylimide (PMI) structural foam that machines exceptionally well using CNC milling, routing, and cutting processes. Its material structure is specifically suited to high-precision machining where dimensional accuracy and surface quality are critical.
When machined correctly, ROHACELL® produces clean features with minimal edge breakout and requires little to no secondary finishing.
Material Structure and Behaviour Under the Spindle
ROHACELL® has a rigid, closed-cell microstructure that provides a high stiffness-to-weight ratio. This structure resists local deformation during machining, even at high feed rates or under aggressive cutting parameters.
Under the spindle, this results in:
- Stable cutting behaviour
- Reduced chatter and vibration
- Accurate feature reproduction
- Consistent part geometry
The material does not smear, tear, or collapse under cutting forces in the way softer or open-cell foams can.
Dimensional Accuracy and Repeatability
Dimensional stability is a defining characteristic of ROHACELL® during CNC machining.
Key benefits include:
- Tight tolerance control across multiple parts
- Repeatable results from batch to batch
- Stable geometry during and after machining
This makes ROHACELL® particularly suitable for precision components such as spacers, cores, tooling inserts, and structural dielectric parts.
Surface Finish and Edge Quality
ROHACELL® machines with clean edges and well-defined features. Tool paths are reproduced accurately, and surface finishes are typically uniform.
Typical outcomes include:
- Minimal edge chipping or tearing
- Low surface roughness without post-processing
- Excellent bond-ready surfaces
In many applications, machined ROHACELL® parts can be bonded or assembled directly without additional surface preparation.
Tool Wear and Machining Efficiency
ROHACELL® is not abrasive and does not contain fillers that accelerate tool wear.
Machining advantages:
- Long tool life
- Reduced heat generation
- Stable cutting conditions
This supports high-throughput machining and consistent quality in production environments.
CNC Machining Parameters and Methods
ROHACELL® is compatible with:
- High-speed CNC milling
- 3-axis and 5-axis machining
- Routing and profiling
- Drilling and pocketing operations
The material supports high feed rates while maintaining accuracy, making it well suited to both prototyping and series production.
Applications of CNC-Machined ROHACELL®
CNC-machined ROHACELL® components are used in applications where precision and performance are non-negotiable.
Common applications include:
- Motorsport aerodynamic cores and inserts
- Aerospace sandwich structures
- RF and antenna spacers
- Composite tooling and patterns
- Lightweight structural components
These applications demand repeatability, accuracy, and predictable material behavior.
ROHACELL® delivers predictable, high-quality results under CNC machining due to its closed-cell PMI structure, stiffness-to-weight efficiency, and dimensional stability. Clean edges, minimal tool wear, and consistent surface finish make it a preferred material in environments where precision and repeatability matter.
For manufacturers working in F1, aerospace, and advanced composites, ROHACELL® remains a proven material that performs reliably under the spindle.
