Sometimes You Need to Transfer Your Mold to Get the Most Out of It. Performance Plastics, LTD. can Help.

October 17, 2019  |  

Having a mold made is a large investment for any size company. Running between $30,000 to $70,000, molds are an investment that need to be reliable the first time, all the time.

But it seems more and more, Performance Plastics is seeing customers looking to transfer their molds because those molds can’t achieve company goals. This blog explores our history of transferring molds made by others to us and how our processing expertise pays off for customers in the long run.

Why Transfer?

“One of our customers has a mold that makes 1 million parts per year for a critical application, but they weren’t getting consistent production from their previous supplier,” says Chris Lawson, chief operating officer at Performance Plastics. “They were worried about the inconsistency of their supply and if that would translate into failure in the field.”

The main reason for transferring a mold from one supplier to another comes down to the supplier’s expertise in using the mold. Generally, the customer isn’t seeing consistency in the parts coming out of the mold and knows that something is missing in the strategy – but they’re not sure what.

“At least half of the customers we currently have started out by transferring their mold to us,” Lawson says.

The Handoff

Like so many others, that million-part customer reached out to Performance Plastics to discuss mold transfer. But the process doesn’t begin with packing the mold into a crate and shipping it to our Cincinnati offices. It starts with defining the problem.

“Does the customer understand why they’re not getting the type of product they need, and do they understand what they perceive the product to be?” Lawson asks. “We spend time with the customer trying to understand what the product should do; what does the customer believe is critical.”

For example, a customer might need “Diameter A” to be perfect. However, production of the mold was driven more by some other product feature.

“We have to understand what’s important to them and why they aren’t getting it out of the product,” Lawson says. “We try to define the problem, where most can only identify the symptoms.”

Once the problem is defined and the mold is transferred, Performance Plastics gets to work … and that starts with running the mold as though it came in new.

“We just want to see what happens with it,” Lawson says. “Sometimes the previous supplier just didn’t follow a robust approach in working with the mold and missed something. We can identify that.”

Performance Plastics uses everything from basic scientific injection molding principles to design of experiment (DOE) concepts. DOE is a branch of applied statistics that deals with planning, conducting, analyzing, and interpreting controlled tests to evaluate the factors that control the value of a parameter or group of parameters. It is a powerful data collection and analysis tool that can be used in a variety of experimental situations.

“Most people don’t understand DOE when they are testing something,” Lawson says. “You’re trying to understand how five different factors interrelate to results that you believe are important, and that’s where we specialize.”

The Transfer Process

Transferring a mold from one supplier to another can take between two and six weeks – although Performance Plastics has done it in as little as three days!

“Once we get our process engineers involved, we can move rather quickly,” Lawson says. “It just depends on if any changes need to be made to the mold itself.”

Performance Plastics has three toolmakers in house that can handle mold modifications to correct errors, and to create fixtures and robotic end effectors if needed.

A lot of the timing revolves around the customer’s ability to supply their own customers. Because the mold is already in use and contracts have been signed, customers need to keep up their inventory of parts to meet demand, all while working to transfer the mold to another supplier who can use it more effectively.

“We understand that it’s painful to transfer suppliers,” Lawson said. “That said, we’ve handled more than 150 mold transfers over the years, and we have the expertise a lot of people are missing.”

To learn more about how Performance Plastics can help transfer your mold, contact Rich Reed, our Vice President of Sales and Marketing, at (513) 321-8404 or [email protected].

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Performance Plastics LTD. Uses Automation and Robotics to Assure Tight Tolerances and Cost Effectiveness

September 30, 2019  |  

Image you’ve just placed an order for two million injection molded parts to be manufactured over the course of a year and each part needs to be exactly the same. Or, that you have a part with a tolerance of under 0.001”. 

How confident are you that the manufacturer you’ve placed the order with can hit your specifications?  

At Performance Plastics, we couple our design expertise with automation and robotics to ensure tight tolerance part quality and consistency, as well as cost effectiveness. 

“Everything starts with the molding process and we’re among the best for getting that process tight,” says Jake Edwards, an automation engineer at Performance Plastics. “After molding, we’re constantly verifying that we’re within specifications. Automation allows us to efficiently inspect 100 percent of the products we make if needed.” 

Keeping It Tight 

For high-volume runs, we make sure every part that goes out the door is within the customer’s spec or our own – whichever is tighter. We measure dimensional tolerance, surface tolerance, even the way parts are positioned so they can go into the end product the same way every time.  

“We have parts that we make where we have to hold the tolerance to under 0.001 of an inch,” Edwards says. “And that can be over a run of 15 million parts throughout the year. We have to have a flat line of consistency.” 

But it’s not just high-volume orders that are checked via automation. Low volume runs with very tight tolerances for parts in critical applications are handled this way too. For example:  

  • In the HVAC industry, we make parts that seal off chemicals in order to prevent dangerous leaks.  
  • In the Industrial space, we make parts for plasma cutters that make sure two different types of gases are mixed correctly right at the nozzle. 
  • In the Medical industry, we make parts that contain tissue samples. They need to be protected from contaminants to guard against false positives or negatives.  

Robotics and Automation 

At Performance Plastics, we use a combination of automation and robotics across everything we do.  

“Robotics is automation,” says Edwards, “But automation is not necessarily robotics.” 

As previously described, automation is used to test tolerances. But we also have hard automation where cylinders, vacuums, and other actuators are moving product from place to place around the production facility – all with no robot in sight.  

However, robotics does make automation simpler. Take overmolding, for example. Many parts include battery contacts that run internally, a metal base, or features made from something other than plastics. A robot is can be fed these parts by an operator or other means. The robot will then place the parts in the mold to have the plastic part molded over top of the inserted non-plastic piece, pull the completed part out and re-insert new, quickly and reliably. 

Cost Savings 

Where automation and robotics comes together is at the bottom line – cost savings. For example, cycle times can be greatly improved because automation allows us to do multiple things at once, such as vision checks and leak checks at the same time.  

And this means one thing for our customers … cost savings.  

“Our reliability has gone up, which turns down the risk for our customers,” Edwards says. “With higher repeatability, the risk to the customer goes down. 

“If a customer finds 3 percent of a 1,000-piece order is out of spec, they’ll return the entire order. Sometimes the customer won’t allow one single piece to be out of spec – one bad part and the whole lot comes back. So, we need to be right the first time.” 

When it comes to robotics, not only can they be faster and more reliable, but they play a role in safety as well. The robotics keep operators out of hazardous environments on the manufacturing floor, which also impacts the bottom line.  

To learn more about Performance Plastics uses automation and robotics, contact Rich Reed, our Vice President of Sales and Marketing, at (513) 321-8404 or [email protected]. 

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Performance Plastics LTD: Advantages of High Performance Polymer Bearings and Bushings

August 6, 2019  |  

Plastic is a fantastic material that is used in practically everything from playground equipment to lawn mowers to vehicles. But what about as a bearing or bushing?

Many engineers resist using plastic bearings, thinking they won’t stand up to harsh environments, extreme temps, heavy loads or high speeds. Some engineers believe in metallic bearings and are reluctant to change. However, high-performance plastic bearings from Performance Plastics are turning heads and changing minds.

Standard Metal Bearings

Polytetrafluoroethylene (PTFE)-lined metal bearings are made up of a thin, self-lubricating layer, embedded with PTFE, which is permanently bonded to an aluminum housing. However, the liner isn’t replaceable and can be scratched off by contaminates, which results in metal-to-metal contact between the bearing and shaft. This increases the coefficient of friction (COF), accelerates wear rates, and increases the risk of shaft damage.

How about injection molding the entire bearing or bushing from FEP, PVDF, or PFA?

High-Performance Plastic Bearings

With advancements in plastics, plastic bearings are gaining in popularity because they are more versatile, economical, and corrosion resistant. PEEK, Torlon® (PAI), PBI (polybenzimidazole), Ultem® (PEI), and PPSU (polyphenylsulfone) are all available as material options and suitable for use in plastic bearings. Plastic bearings are made of a thermoplastic alloy with a fiber matrix and solid lubricants, which account for their superior strength and consistently low COF.

High-performance plastic bearings offer a great many advantages:

  • Cost savings, first and foremost. High-performance plastic bearings reduce overall cost because they resist wear, reduce maintenance costs, and can replace more costly alternatives.
  • No need to lubricate. These bearings are self-lubricating, with lubricants embedded in the tiny chambers of the composite material. This eliminates the costs of both additional lubricants and continual maintenance.
  • Plastic bearings can be reinforced with carbon fiber or fiberglass and can operate continuously at temperatures between -40°F and 500°+ F. But their thinner walls are better at dissipating heat. Plus, they’re less likely to deform under heavier weights.
  • Corrosion Resistant. Plastic bearings are specifically designed to operate in harsh environments, surviving daily washdowns and caustic chemicals. Plus, their self-lubricating nature eliminates seal failure and contamination.
  • Consistent COF. These bearings are designed to maintain a low COF over their lifetime, while their metal-backed counterparts can become scratched and increase the COF.
  • Lighter weight. Plastics are significantly lighter than their metal alternatives, which can be up to five times heavier.
  • Plastics can dampen vibrations with lubrication, becoming virtually silent.

To learn more about high-performance plastic bearings from Performance Plastics, contact Rich Reed, our Vice President of Sales and Marketing, at (513) 321-8404 or [email protected].

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Performance Plastics LTD Adds New Service to its offering

July 17, 2019  |  

Industrial CT Scanning can help during multiple manufacturing stages

CINCINNATI, Ohio, April 30, 2019 ― Performance Plastics is pleased to announce a new service that helps round out its offering: industrial computed tomography (CT) scanning.

Performance Plastics CT Scan ServicesIndustrial CT scanning gives customers access to the inner workings of a part without having to destroy the original. The scanner rotates the part 360 degrees and uses X-rays to create a precise 3D model. This allows for a thorough analysis of object dimensions, porosity, wall thickness, assembly defects, comprehensive comparisons, and reverse engineering.

The CT scan can then be compared to the CAD model and to other parts. Plus, it can easily analyze surface variations and provide cross sections to reveal hidden features.

Performance Plastics offers a variety of CT scan-related services:

  • Part-to-CAD comparisons create a precise overlay of the scanned part to the original 3D part model database
  • Part-to-part comparisons provide an overlay of two scanned parts to reveal dimensional deviation
  • Void and inclusion analysis provides material and defect analysis showing void or inclusion size and locations
  • Wall thickness analysis measures slight changes in the wall stock of complex parts without destructive testing
  • Dimensional analysis provides full article inspections and reporting
  • Reverse engineering capabilities that generate a 3D CAD file

“Industrial CT scanning can be necessary during five different manufacturing stages,” said Rich Reed, Vice President of Sales and Marketing. “When you’re in pre-production, it can help with the project design and analysis. During production, you can use CT scanning to evaluate consistency. At the failure investigation stage, it will find defects. The CT scanner can run repeatability tests when you’re doing inspections. And if you need design adjustments or are doing further R&D, it can help with reverse engineering.”

As for what Performance Plastics can handle when CT scanning:

  • Maximum part size is 300mm diameter x 350 mm tall
  • Scan time is typically less than one hour
  • Accuracy (using Calypso) of 9+L/50 microns
  • X-ray-based measurement system is non-contact
  • Parts do not require potting

About Performance Plastics

We are problem solvers. We design and manufacture injection molded parts made with ultra-high-performance plastics such as Torlon®, PEEK, Ultem® and fluoropolymers. (FEP, PFA, PVDF). We specialize in molding parts with complex geometries and very tight tolerances for critical applications such as aerospace/defense, medical, and energy. We achieve this by combining a unique product design approach with proprietary process technology and state-of-the art quality control that provides our customers the “lowest cost solution.” Our engineers deliver results where others say, “it can’t be done.”

 

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Don’t Machine When You Can Injection Mold with Performance Plastics Ltd.

May 24, 2019  |  

Performance Plastics specializes in precision injection molding of difficult parts, eliminating the need to machine. Our precise production process gives us the ability to injection mold difficult parts made from high performance plastic materials. If it can be molded, we can do it.
High performance plastic materials have ideal properties when it comes to durability. Plastics like polytetrafluoroethylene (PTFE/Telfon®) are known for their dielectric strength, low dissipation, chemical resistance, outstanding performance at elevated temperatures, and coefficient friction. However, their unique properties can make machining PFTE quite difficult. Dimensional changes, burrs, and consistency of machining can all be factors when you are creating a part out of these materials. Performance Plastics has found a way around the complications of machining PTFE by injection molding of other fluoropolymers.

At Performance Plastics, we are experts at precision injection molding. We have developed proprietary tool design software, processes and equipment enabling us to injection mold components having complex geometries made from challenging ultra- and high-performance thermoplastic materials and highly loaded compounds. We utilize a unique combination of extensive material knowledge, mold flow analysis, a design system and process expertise to eliminate or minimize the need for secondary operations.

The switch from a machined part to an injection molded part can be very beneficial to you. Not only does injection molding help lower costs, it also allows you to have highly efficient production, complexity in your part design, and enhances your strength. The ability to produce the parts at a very high level with a high output rate helps with cost efficiency and effectiveness. Injection molding can handle extremely complex parts, and uniformity, as well as the ability to make millions of virtually identical parts. Engineers can determine if the part needs to be flexible or rigid so that they can select the right material and adjust the integrating ribs or gussets. With the vast variety of materials and colors, making your color options almost endless.

Injection molding isn’t for every project, but it can be tremendously beneficial if you’re an engineer using more than 20,000 pieces of the same part year over year. At Performance Plastics, we serve a variety of industries, from Medical to Energy, Aerospace & Defense to Industrial, Electronics to Food & Beverage.

To learn about how precision injection molding can replace machined PTFE parts, contact Rich Reed, our Vice President of Sales and Marketing, at (513) 321-8404 or [email protected]

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It’s Not Tight Tolerance Unless You Can Measure It!

April 30, 2019  |  

As you’re designing and manufacturing your next application, wouldn’t it be ideal if you could analyze all the parts, compare them to the original drawings and get results quickly, without damage? At Performance Plastics, we have the ability to do this through industrial computed tomography (CT) scan. Giving us the ability to measure all aspects of your part, without having to damage it.

Industrial CT scanning gives you access to the inner workings of a part without having to destroy the original. The scanner rotates the part 360 degrees and uses X-rays to create a precise 3D model. This allows for a thorough analysis of object dimensions, porosity, wall thickness, assembly defects, comprehensive comparisons, and reverse engineering.

Performance Plastics CT Scan ServicesPerformance Plastics CT Scanner

The CT scan can then be compared to the CAD model and to other parts. Plus, it can easily analyze surface variations and provide cross sections to reveal hidden features.

Performance Plastics now offer a variety of CT scan-related services:

  • Part-to-CAD comparisons create a precise overlay of the scanned part to the original 3D part model database
  • Part-to-part comparisons provide an overlay of two scanned parts to reveal dimensional deviation
  • Void and inclusion analysis provides material and defect analysis showing void or inclusion size and locations
  • Wall thickness analysis measures slight changes in the wall stock of complex parts without destructive testing
  • Dimensional analysis provides full article inspections and reporting
  • Reverse engineering capabilities that generate a 3D CAD file

Industrial CT scanning can be necessary during five different manufacturing stages. When you’re in pre-production, it can help with the project design and analysis. During production, you can use CT scanning to evaluate consistency. At the failure investigation stage, it will find defects. The CT scanner can run repeatability tests when you’re doing inspections. And if you need design adjustments or are doing further R&D, it can help with reverse engineering.

As for what Performance Plastics can handle when CT scanning:

  • Maximum part size is 300mm diameter x 350 mm tall
  • Scan time is typically less than one hour
  • Accuracy (using Calypso) of 9+L/50 microns
  • X-ray-based measurement system is non-contact
  • Parts do not require potting

At Performance Plastics, we are problem solvers. We design and manufacture precision injection molded parts made with ultra-high-performance plastics such as Torlon®, PEEK, Ultem® and fluoropolymers. (FEP, PFA, PVDF). We specialize in molding parts with complex geometries and very tight tolerances for critical applications such as aerospace/defense, medical, and energy. We achieve this by combining a unique product design approach with proprietary process technology and state-of-the art quality control that provides our customers the “lowest cost solution.” Our engineers deliver results where others say, “it can’t be done.”

To learn more about if a CT scan can help your application, contact Rich Reed, our Vice President of Sales and Marketing, at (513) 321-8404 or [email protected]

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Performance Plastics, LTD. Adds to Its Line of EnduroSharp® Accessory Tools

March 14, 2019  |  

Products will be on display at the MRO Americas Aviation Week Show next month

Performance Plastics is pleased to announce two additions to its EnduroSharp® line of accessory tools: the EnduroSharp® Torlon® Adhesive Reamer (TAR) and Adhesive Cutter (TAC).

"EnduroSharp<sup

EnduroSharp® TAR tools are non-metallic, multi-fluted, straight-walled reamers. They are used to remove non-metallic debris such as cured sealants and adhesives from fastener and bushing holes in metallic or composite structures without damaging the structures. Available in four different sizes, the reamers have a hex drive mounting feature, allowing it to be used with low RPM battery-powered screwdrivers (200 rpm or less), ratcheting screwdrivers or the EnduroSharp® Ratcheting T-Handle with Keyless Chuck.

EnduroSharp® TAC tools are designed to be used with the standard (non-segmented) and tetherable (segmented) mandrels. They can also be used with electric and pneumatic drills rated at 600 RPM or less. TAC tools are supplied in EnduroSharp® surface preparation tool kits.

“These new EnduroSharp® tools are an important expansion of our line of aircraft maintenance tools,” said Rich Reed, Vice President of Sales and Marketing. “Performance Plastics has always been known for our injection molding expertise. The bottom-line advantage is that the customer can now count on us for our ability to solve all of their engineering challenges with our products and services.”

"EnduroSharp<sup

These new products will be on display at the MRO Americas Aviation Week Show April 9-11, 2019. Performance Plastics will be exhibiting in Booth 5117, in Building B, Halls 1-5 of the Georgia World Congress Center, in Atlanta, GA. Additionally, on display in the Performance Plastics’ booth will be the company’s complete line of Torlon® Aircraft Maintenance Tools. These nonmetallic scraper tools hold a superior edge and are extremely durable for removing sealants, adhesives, and coatings. What’s more, maintenance personnel no longer have to resort to sharpened putty knives, scribes, and utility blades.

To learn more, please visit www.performanceplastics.com/endurosharp/accesssories or contact Rich Reed, our Vice President of Sales and Marketing, at (513) 321-8404 or [email protected].

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Flexibility and Strength: Performance Plastics Ltd. and Nylon Offer You Both

February 13, 2019  |  

Nylon might not always be the first material that comes to mind when you think about making products for compressors and pumps, or military and defense applications … unless you’re working with Performance Plastics Ltd.

Thermoplastic precision Nylon Parts

The world’s first commercially successful version of nylon was created in 1935. Over the decades, it proved to be a lightweight, heavy-duty industrial and engineering plastic replacement for metals that was resistant to both heat and corrosive chemicals. Performance Plastics sees nylon as a fantastic material that offers excellent flexure and bending fatigue strength, which makes it ideal for parts that undergo intermittent loading. With wear resistance far greater than many metals and other thermoplastics and a low coefficient of friction, nylon is ideally suited for use in slides, bearings and other devices that must stand up to high levels of motion and wear.

Today, a wide range of nylon resin formulations and combinations with other polymers are available, as well as glass-, carbon-, and mineral-reinforced versions. For example, Minlon® mineral-reinforced nylon provides greater dimensional stability and creep resistance than unreinforced nylon, and lower warpage than glass-reinforced nylon. As a result, it is popular for use in compressor valves and big industrial parts, as well as in demanding automotive applications.

Performance Plastics has seen nylon’s applications grow to include a range of fluid handling pumps to move water, acids, lubricants, solvents, chemicals, and fuels in automotive, military and aerospace environments. Although pump makers traditionally used various metals for pump housings, shaft guides, impellers, seals, bushings and other elements, the desire to reduce pump weight and material and processing costs has led many to opt for various nylon formulations instead. In fact, Performance Plastics can use nylon to offer pump makers a combination of physical strength, wear resistance, self-lubrication, and high cost-effectiveness.

Choosing the optimal nylon resin for a pump application depends on several factors, including the levels of pressure, temperature, and speed involved. In addition, the abrasiveness of the liquids or slurries involved, the degree of contamination that can be tolerated, and projected uses for the pump must also be considered.

Nylon’s toughness and elongation properties make it suitable for designs that involve snap-fits or press-fits. Injection-molded nylon parts from Performance Plastics are well-suited to secondary machining processes such as turning, drilling, tapping and grinding, as well as ultrasonic insertion, ultrasonic welding, pad printing, and assembly.

To discover how Performance Plastics is partnering with world-class polymer scientists and industry leading material suppliers to delivery nylon solutions, visit our website at https://performanceplastics.com or contact Rich Reed, our Vice President of Sales and Marketing, at (513) 321-8404 or [email protected].

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PEEK Injection Molded Plastic is Taking the Place of Metal

January 23, 2019  |  

Performance Plastics provides a solution to avoid metal when designing your new part. Perfecting injection molding processes since 1980, PPL has an extensive knowledge of how to create plastic parts equivalent to metal. A high-performance plastic, such as Polyetheretherketone (PEEK), is ideal for parts that demand the high strength of metal, while also being lightweight and resistant to corrosion.

PEEK is a mainstay material for a growing variety of applications in many different industries. Its popularity is due to excellent friction and wear characteristics, extended durability under punishing environmental conditions, including high temperatures, abrasion and aggressive chemical environments.

Unfilled PEEK resins emit extremely low levels of smoke and toxic gas when exposed to a flame. Glass and carbon reinforced PEEK resins offer high thermal stability and are among the strongest thermoplastics in the market.

PEEK has a long list of outstanding characteristics making it one of the most popular alternatives to metal:

  • High mechanical strength and dimensional stability
  • Excellent long-term creep and fatigue properties
  • Excellent resistance to harsh chemicals
  • Withstands a wide range of acids and bases; high resistance to hydrocarbons and organic solvents
  • High wear resistance
  • Low coefficient of friction; high abrasion and cut-through resistance
  • Low moisture absorption and permeability
  • Resistant to high-pressure steam, fresh water and salt water
  • Excellent performance at high temperatures
  • Suitable for continuous-use temperatures up to 500°F
  • High electrical integrity
  • Displays consistent properties over a range of frequencies and temperatures; depending on the grade of resin chosen, PEEK parts can be insulating, conducting or static dissipative
  • Low smoke and toxic gas emission
  • Inherently flame retardant without the use of additives; low toxicity of combustion gases

Performance Plastics uses various grades of PEEK resin as metal replacements in applications where few other fluoropolymers would be considered. PEEK is widely used in industries such as: aerospace (commercial and defense), automotive, marine, industrial and energy (fossil fuel and renewable).

To discover how PEEK polymer resins can make the transition from metal to thermoplastic easier contact Rich Reed, Vice President of Sales and Marketing, at (513) 321-8404 or [email protected]

PEEK Resin Thermoplastic Component

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