Flush Cutter Recommendations for Plastic Tabs in Circular Hole?

[YoshiMoshi3]

Can someone please recommend some flush cutters for plastic? I'm trying to cut off these four plastic tabs in each circle. The circles are about 21 mm in diameter (slightly larger than). I don't know if "special" flush cutters would make it easier for me, where "flush" is a circular surface instead of a flat one?

 

[PCustoms]

How many do you have to cut?

1/4" Template bit in a router table is what I would do.

 

[YoshiMoshi3]

How many do you have to cut?

1/4" Template bit in a router table is what I would do.

Ah I don't have a router table. Flush cutters is a no go?

I need to cut 120 circles so 480 tabs, yikes.

 

[larry_g]

A lot depends on the required 'look' after tab removal, the material the product is made out of, and how many you have to do. Do you need to remove just what protrudes into the circle or also what protrudes below the circle? Me for limited amount and soft plastic I would use a set of flush cutters.

 

[Ltay]

Would a deburring tool work here?

I've been using one for cleaning up some 3D prints, but that's just cleaning up little strands and edges here and there. Not sure how it would do in this specific case.

https://www.amazon.com/AFA-Tooling-Deburring-Printed-Printing/dp/B0B7611J5Y?tag=atomicindus08-20

 

[Old tool guy]

Ah I don't have a router table. Flush cutters is a no go?

I need to cut 120 circles so 480 tabs, yikes.

Don’t need a router table. Get a small palm router and a 1/4” bottom bearing flush cutting bit. Once the depth is adjusted, you’re looking at about 10 seconds per cavity.

 

[GeoBruin]

Don’t need a router table. Get a small palm router and a 1/4” bottom bearing flush cutting bit. Once the depth is adjusted, you’re looking at about 10 seconds per cavity.

Forstner bit the size of the hole.

 

[YoshiMoshi3]

A lot depends on the required 'look' after tab removal, the material the product is made out of, and how many you have to do. Do you need to remove just what protrudes into the circle or also what protrudes below the circle? Me for limited amount and soft plastic I would use a set of flush cutters.

I only need to cut what protrudes into the circle.

 

[PCustoms]

Ah I don't have a router table. Flush cutters is a no go?

I need to cut 120 circles so 480 tabs, yikes.

You cutting flush to the ID, to the surface or both?

Is this a hobby project or rework/degating a molded part?

 

[YoshiMoshi3]

You cutting flush to the ID, to the surface or both?

Is this a hobby project or rework/degating a molded part?

Hobby project. I'm cutting the tabs off. So that way I have a 21 mm circle.

The circles are 21 mm but there are four plastic tabs that stick into the middle.

 

[YoshiMoshi3]

Don’t need a router table. Get a small palm router and a 1/4” bottom bearing flush cutting bit. Once the depth is adjusted, you’re looking at about 10 seconds per cavity.

Ah so a palm router and a 1/4 " bottom bearing flush cutting bit that is 21 mm in diameter would work it seems?

 

[PCustoms]

Ah so a palm router and a 1/4 " bottom bearing flush cutting bit that is 21 mm in diameter would work it seems?

No

That would be a huge bit, hard to control

Something like this:



Depending on the part and how you're going to orient it you might want the hearing on the order side.

My hesitation doing this freehand we would be keeping the router flat. The table spreads out/supports the uneven surface of the part

 

[T444e]

I have a Knipex 45 degree flush cutters that I use on cable ties that work well. That style may work for you but I don't know the model number.

 

[Old tool guy]

My hesitation doing this freehand we would be keeping the router flat. The table spreads out/supports the uneven surface of the part

Thought of that. The hole is only 21 mm dia … 7/8” … the router base plate is going to span much more than that.

 

[Old tool guy]

Forstner bit the size of the hole.

Only works if the bit is exactly the right size, and is aligned exactly right. Not likely to be a success.

 

[KnurledNut]

Mini flush cutter bit in a router table. Fast and accurate.

1/8 shank:


1/4 shank:

 

[Rabid Badger]

If you have a 3d printer you could print custom cell spacers rather than modify those.

 

[GeoBruin]

Only works if the bit is exactly the right size, and is aligned exactly right. Not likely to be a success.

He knows the ID of the holes and can purchase an appropriate bit. He can align it exactly by starting the bit through the other side without the tabs. The hole will act as a guide for the bit.

 

[sparky 1971]

How about running a hole saw through from the other side? Of course, that is dependent on the right sized saw existing.

Looks like the above poster beat me to it.

 

[GeoBruin]

How about running a hole saw through from the other side? Of course, that is dependent on the right sized saw existing.

A (sharp) hole saw would work just as well. High rpm, slow feed.

 

[MovingAlong]

Homemade flap wheel, sand them flush.

 

[The Cobbler]

how hard or brittle is the plastic?
I'd be trying to find a cutter of some sort to punch them out , like a pc of pipe sharpened or a curved chisel etc.
as mentioned, a hole saw , forstener bit etc. a heated knife to cut them .
a 3/4" hole saw, or even a step bit.
then clean it up with a sanding drum on a drill

 

[The Cobbler]

here, diamond bit hole saw

 

[PCMusicGuy]

I've had good luck with Xuron cutters in terms of performance/dollar. Depending on the thickness of the tabs, you may be better off with a small hobby knife or hobby saw with a flexible enough blade.

 

[seber]

Use a 21mm hand reamer. It is made for this purpose.

Gavan Tools

Gavan Tools

gavantools.com

 

[PCustoms]

Use a 21mm hand reamer. It is made for this purpose.

Gavan Tools

Gavan Tools

gavantools.com

I've never seen a reamer used on an interrupted surface with large protrusions like this

 

[scooby074]

Another vote for the knipex" fur plastik" 45* 72.11.160 flush cutters.