Computed Tomography Measures Tighter Tolerances – Metrology News

April 8, 2021  |  , , ,

Computed Tomography Measures Tighter Tolerances

Metrology News

 

 

 

 

 

 

 

 

Plastic injection molding continues to become more and more sophisticated with part tolerances becoming tighter and tighter. Initially, tight tolerance was defined as +/-.002 inches (0.0508 mm) and a very tight tolerance is +/-.001 inches (0.0254 mm) But today there are many factors that impact tight tolerance including part complexity and size, resin selection, tooling, and process conditions. So, getting the mold, part design, material selection and process correct is crucial when working with a product that requires tight tolerances.

Tight tolerances are essential when manufacturing complex parts, especially in the aerospace & defense, medical & life sciences, and diversified industrial sectors.  A few thousandths of an inch can be the difference between a component that fits and one that does not – if tight tolerances are not achieved properly the resulting products may underperform. So, it is critical that clients understand tight tolerances and their underlying objectives. Performance Plastics has parts in production that are +/-.0004 inches (0.01016 mm). Parts are measured in their Metrology lab with a CT Scanner. Engineers use Zeiss metrology equipment to analyze every aspect of parts and the problem at hand, not just the data on the part dimensions and the dimensional tolerances.

Benefits of Tight Tolerances

There are many benefits to manufacturing parts with tight tolerances. It ensures that parts work together smoothly and fit as intended in their final form; parts mesh well and deliver enhanced functionality.   They produce lower failure rates and result in higher client satisfaction. Tight tolerances can also result in fewer post-molding processing requirements.  Additionally, tight tolerances allow for parts to be transitioned from metal to plastic, reducing overall weight and cost of the final product. This can be very advantageous in some industries, such as aerospace and defense.

Design for Tight Tolerances

Not every plastic injection molding project requires tight tolerances, and some organizations insist on tight tolerances for non-critical features.  Tight tolerance should only be required in instances where they are critical.  Many products require standard tolerancing because the consequences of failure are low.  As a general rule, designers should keep tolerances as large as possible while maintaining the desired functionality of the part.

Materials for Tight Tolerances

Additionally, material selection is a critical element in achieving tight tolerances.  Certain resins perform better under certain circumstances.  An experienced design engineer can guide a client in choosing the most affordable material that will deliver the best result.  So, it’s critical to bring in an experienced team early in the design process.

By engaging a production team during the design phase, part functionality, material selection and design can be discussed upfront, and the team can jointly develop a manufacturing process and correct materials that will produce high-precision components. It is crucial for organizations to partner with an experienced injection molder, who has expertise; the design and manufacturing teams should be integrated to allow manufacturability issues to be identified and addressed during the design process – thus saving significant time and unnecessary cost.

Establishing the right process and correct materials for each product and developing repeatability are key to manufacturing tight tolerance parts. While every application is different, there are some process and material conditions that impact tolerances. For example, quick cavity filling and uniform cooling at the desired temperature are conditions that are crucial to achieving repeatability, and thus, parts with tight tolerances.

 

Posted from Metrology News – April 8, 2021

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Tight Tolerances & Material Selection

April 7, 2021  |  , , , , , ,

Plastic injection molding continues to become more and more sophisticated with part tolerances becoming tighter and tighter. Initially, tight tolerance was defined as +/-.002 inches and a very tight tolerance is +/-.001 inches. But today there are many factors that impact tight tolerance including part complexity and size, resin selection, tooling, and process conditions. So, getting the mold, part design, material selection and process correct is crucial when working with a product that requires tight tolerances.

Tight tolerances are essential when manufacturing complex parts, especially in the aerospace & defense, medical & life sciences, and diversified industrial sectors.  A few thousandths of an inch can be the difference between a component that fits and one that does not – if tight tolerances are not achieved properly the resulting products may underperform. So, it is critical that clients understand tight tolerances and their underlying objectives. Performance Plastics has parts in production that are +/-.0004 inches. Parts are measured in their Metrology lab with a CT Scanner.

 

Benefits of Tight Tolerances

There are many benefits to manufacturing parts with tight tolerances. It ensures that parts work together smoothly and fit as intended in their final form; parts mesh well and deliver enhanced functionality.   They produce lower failure rates and result in higher client satisfaction. Tight tolerances can also result in fewer post-molding processing requirements.  Additionally, tight tolerances allow for parts to be transitioned from metal to plastic, reducing overall weight and cost of the final product. This can be very advantageous in some industries, such as aerospace and defense.

Design for Tight Tolerances

Not every plastic injection molding project requires tight tolerances, and some organizations insist on tight tolerances for non-critical features.  Tight tolerance should only be required in instances where they are critical.  Many products require standard tolerancing because the consequences of failure are low.  As a general rule, designers should keep tolerances as large as possible while maintaining the desired functionality of the part.

Materials for Tight Tolerances

Additionally, material selection is a critical element in achieving tight tolerances.  Certain resins perform better under certain circumstances.  An experienced design engineer can guide a client in choosing the most affordable material that will deliver the best result.  So, it’s critical to bring in an experienced team early in the design process.

By engaging a production team during the design phase, part functionality, material selection and design can be discussed upfront, and the team can jointly develop a manufacturing process and correct materials that will produce high-precision components. It is crucial for organizations to partner with an experienced injection molder, who has expertise; the design and manufacturing teams should be integrated to allow manufacturability issues to be identified and addressed during the design process – thus saving significant time and unnecessary cost.

Establishing the right process and correct materials for each product and developing repeatability are key to manufacturing tight tolerance parts. While every application is different, there are some process and material conditions that impact tolerances. For example, quick cavity filling and uniform cooling at the desired temperature are conditions that are crucial to achieving repeatability, and thus, parts with tight tolerances.

Performance Plastics is highly skilled at designing and molding using high performance materials such as PEI-Ultem®, PAI-Torlon®, Ryton® PPS Plastic, PEEK, and Fluoropolymers such as FEP, PFA, and PVDF.  We work with our customers to solve technically challenging problems.   We can propose materials to implement part functionality in the design stage of development. We offer manufacturing solutions such as a clean room, the ability to offer direct gating of fluoropolymers, high volume production, visual inspection, and automated facilities.

For more information and solutions, please contact Rich Reed, Vice President of Sales & Marketing at 513-321-8404 or email [email protected]

 

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Introducing the EnduroSharp® Nutplate Abrasion Tool (NAT)

April 1, 2021  |  , ,

 

For decades, maintenance personnel have searched for a non-metallic scraper tools or sealant remover tools that could hold an effective edge, but not damage aircraft structures, like composite and aluminum.

That’s why Performance Plastics created the patented EnduroSharp® line of Torlon® Maintenance Tools. Suitable for aircraft, automotive, marine and windmill structures, 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.

EnduroSharp® is pleased to announce our new and improved Nutplate Abrasion Tool (NAT).  An alternative to traditional abrasion methods, this tool was specifically designed to allow maintainers to quickly abrade the bond surface of CR series nutplates. The tools radially abrade the bond surface of the nutplate, ensuring that 100% of the bond surface is abraded uniformly in a manner of minutes.

The NAT kit consists of six components:

  • One each upper handle (top)
  • One each lower handle (base)
  • Four each nutplate base inserts

The NAT kit is available with a convenient carrying case.  The rugged case comes with a high-density custom foam insert for easy inventory and protection.

For more information and solutions, please contact Rich Reed, Vice President of Sales & Marketing at 513-321-8404 or email [email protected]

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Ultem – A Powerhouse Polymer

March 24, 2021  |  , , , , ,

Ultem PEI Polyethermide thermoplastic component

When trying to choose the correct polymer for your application, understanding the materials can help you make your decision.  For parts that require superior strength and durability, Ultem® is often a great choice.

 Ultem® is a semi-transparent high strength plastic material that can operate in high service temperature environments.  It is the ideal choice for demanding, high heat applications and can withstand continuous operating temperatures of 340 degrees F while maintaining strength and rigidity.

 Ultem® is a member of the PEI (polyetherimide) family of thermoplastic resins. It provides a unique balance of mechanical properties and processability that gives engineers superior flexibility and freedom in design. Ultem is available in a variety of grades that provide enhanced chemical, heat, and elasticity benefits. It also features high tensile strength, stiffness, strength to weight ratio and dimensional stability.

Ultem® is the high-performance polyetherimide material of choice for many aerospace, aircraft, medical and pharmaceutical applications, including medical components. It offers exceptional mechanical properties and exhibits natural flame resistance and extremely low smoke generation.

  • Heat, solvent and flame resistant
  • High dielectric strength and stability
  • Excellent mechanical properties
  • Rigid and strong
  • Exceptional resistance to environmental forces

Performance Plastics is highly skilled at designing and molding using high performance materials such as Ultem®, Torlon®, PEEK, POM, and PPS.  We work with our customers to solve technically challenging problems.   We can propose materials to implement part functionality in the design stage of development. We offer manufacturing solutions such as a clean room, the ability to offer direct gating of fluoropolymers, high volume production, visual inspection and automated facilities.

For more information and solutions, please contact Rich Reed, Vice President of Sales & Marketing at 513-321-8404 or email [email protected]

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Insert Molding vs Overmolding

March 4, 2021  |  ,

Insert Molding and Overmolding are very similar processes, but there are distinct differences between the two techniques.  Insert molding is a slightly faster one step process because two plastic materials are molded at the same time, while overmolding is a two-step process where two separately molded parts are combined to enhance the parts performance.

Insert molding is a process which adds metal parts to injection molded parts during molding rather than after the parts have cured.  This reduces the time for post-molding manufacturing/assembly operations. Inserts are placed into the mold cores or cast into the molds themselves. After the mold closes, plastic pellets are plasticized in the injector barrel and shot into the mold, the plastic material flowing around the captured inserts. Once the plastic hardens, the pieces are ejected from the mold, with the inserts now enclosed in the parts. Insert molding is a single-shot process

Insert molding is a common manufacturing method for producing connectors, electronic sockets, in addition to in making parts that are assembled with threaded fasteners. Insert molding is used to provide protective surfaces on many aerospace, defense, and medical/surgical devices.

Insert molding is also the term used to describe the overmolding technique of adding a layer of plastic material onto an existing metal or plastic part.  Here, also, the metal or plastic part is placed into a single-shot injection mold and the over-mold material is injected around it.

Overmolding is an advanced plastic injection technique that creates parts from two or more materials. Typically referred to as “in-mold assembly”, overmolding can be facilitated by either using the insert molding technique, or a multi shot molding technique.

Plastic overmolding, sometimes called multi-shot molding, adds additional material such as thermoplastic elastomer (TPE). Multi-shot molding is usually performed by way of multi-barrel injection molding machines, the process adding additional material shortly after the base is formed to create strong bonds between materials. Plastic overmolding serves to eliminate steps in the manufacturing process while creating enhanced injection molded products.

Depending on the materials selected for the base and the over-mold, materials may be bonded chemically or mechanically.  Inserts made of brass are common, but steel and stainless steel are also used.  Many of the inserts are knurled on the outside or have special shapes that hold the insert in place. Among the many materials that are suited to overmolding, polycarbonate, ABS, Ultem, and nylon. Over-mold materials include PEEK (Polyetheretherketone), FEP & PFA Fluoropolymers, (Neoflon, Polyflon) and PEI (Polyetherimide) Ultem.

Multi-shot overmolding has many applications such as medical instruments where it can provide enhanced grip, sterilization, moisture protection, and so on.  Automobile and Aerospace manufacturers use overmolding to reduce the need for additional assembly steps that would require using adhesives.

Insert Molding and Overmolding are very similar but have distinct differences.  Insert molding is a one step process, while overmolding is a two-step process where two separately molded parts are combined to enhance the parts performance.

 

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Injection Molded PFA & PPSU in the Lithium Ion Battery

March 3, 2021  |  ,

The Lithium Ion Battery industry has begun using more and more plastic parts in their manufacturing processes. Most batteries intended for light vehicle usage now have 50% more plastic materials than they did even 10 years ago.  Some batteries have entirely plastic formulations ranging from the electrolyte (polymeric electrolytes) to the casing.  This is due to the very low weight of plastics as compared to metals. Plastic incorporation in batteries increases the electrolyte efficiency if used in polymeric electrolytes.

Commercially available lithium-ion batteries also use plastics. Plastic components incorporated in batteries include separators, gaskets, and casing components. Plastics have good shock absorbing characteristics and prevent damage to the basic cell unit from minor accidental shocks. Also, plastics such as Teflon® PFA, Ultem® PEI, and PPSU have high temperature resistance, corrosion resistance, and are electrical insulators so they are excellent at preventing short-circuit and “rapid disassembly.”

There has been a major shift from metal to resins in gasket manufacturing. Gaskets can be made from Ultem®, Ryton plastic and Fluoropolymers like PFA because of high heat resistance, chemical resistance, and ability to mold thin walls (.012”). Plastic parts may also lower the cost of production of batteries and may eventually replace most metallic components of batteries.

Performance Plastics is highly skilled at designing and molding high performance materials such as FEP/PFA, Ultem®, Torlon®, PEEK, POM, and PPS.  We work with our customers to solve technically challenging problems.   We can propose materials to implement part functionality in the design stage of development. We offer manufacturing solutions such as a clean room, the ability to offer direct gating of fluoropolymers, high volume production, visual inspection and automated facilities.

For more information and solutions, please contact Rich Reed, Vice President of Sales & Marketing at 513-321-8404 or email [email protected]

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How to Pick the Best Molding Partner for your Application

February 25, 2021  |  , , , ,

At Performance Plastics, we understand that working with a qualified molding company is crucial to your company’s success.  It is vital to find a team to support your company’s mission and commitment to delivering quality products on time.  We have found over time, that there are three essential components that should weigh in your decision-making process when choosing a molder for your next application: Education, Trust and Quality.

Education

Is your molding partner educated about your company and your products?  Do they understand your needs and goals?  Do they understand advanced materials and their properties?  Understanding resins and best molding practices including raw materials, drying time, heat history and molding temperatures will affect the outcome and quality of your application.

Trust

Trust is important in any business relationship – especially one that reflects on your business.  Do you trust your molding partner to properly do the job?  Open and continuous communication with key management of your molding partner is crucial to the success of any application.  Your team should keep you informed of market conditions pertaining to raw materials, new techniques, and opportunities for improvement?

Quality and Quantity

Quality and Quantity, both are important to your business.  Your customers rely on you for quality, dependable parts, but you must rely on your team for an on-time and dependable process.  Dependable processes, such as quality procedures, run rates and material quality control produce quality parts.

Performance Plastics, located in Cincinnati, OH has over 30 years’ experience molding tight tolerance advanced plastics such as Fluoropolymers (FEP/PFA Torlon, Peek & Ultem) for many industries.  We have developed proprietary processes enabling injection molding of parts that are thin walled, with tight dimensional tolerances, and complex geometries.

Education, Trust and Quality.  Think about these questions when choosing your molding partner. Remember – education, trust, communication, and quality of work are vital to a long-lasting business relationship. Ask the questions and get some answers. This will assist you in finding and maintaining a dependable partnership.

For more information and solutions, please contact Rich Reed, Vice President of Sales & Marketing at 513-321-8404 or email [email protected].

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PPL Receives It’s ISO 9001-2015 Renewal

February 4, 2021  |  , ,

Performance Plastics LLC is pleased to announce the renewal of our ISO 9001:2015 certification, valid from March 2021 through March 2024. The ISO 9001:2015 Standard for Quality Management System is applicable to all our processes including development, sales, production, service and after sales.

At Performance Plastics, our Quality Policy revolves around ensuring that requirements are met while continually improving our Quality Management System. Creating customer satisfaction is our number one goal. The ISO 9001 standard is based on several quality management principals including a strong customer focus, the motivation and implementation of top management, the process approach and continual improvement. ISO 9001 ensures that customers get consistent, good-quality products and services, which in turn ensures your satisfaction. Each of our custom projects receives the same attention to quality.

Performance Plastics, located in Cincinnati, OH has over 30 years’ experience in molding tight tolerance advanced plastics such as Fluoropolymers (FEP/PFA Torlon, Peek & Ultem) for many industries. We have developed proprietary processes enabling injection molding of parts that are thin walled, with tight dimensional tolerances, and complex geometries. For more information and solutions, please contact Rich Reed, Vice President of Sales & Marketing at 513-321-8404 or email [email protected].

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Advantages of Industrial CT Scanning in the Design Process

February 3, 2021  |  ,

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 damaging your samples? At Performance Plastics, we offer the services of industrial computed tomography (CT) scan. This provides us the ability to measure all aspects of your part, without having to damage it.

Industrial CT scanning in the design process 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.

The CT scan can then be compared to the CAD model and to other parts. In addition, 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 provide 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

Performance Plastics, located in Cincinnati, OH has over 30 years’ experience in molding tight tolerance advanced plastics such as Fluoropolymers (FEP/PFA Torlon, Peek & Ultem) for many industries.  We have developed proprietary processes enabling injection molding of parts that are thin walled, with tight dimensional tolerances, and complex geometries. For more information and solutions, please contact Rich Reed, Vice President of Sales & Marketing at 513-321-8404 or email [email protected].

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Designing and Molding Complex Plastic Parts

January 27, 2021  |  , , , , , ,

Every project has its own needs and goals.  Complex geometries involving fine details or sharp corners often cannot be achieved by traditional plastic molding. Advanced plastic injection molding processes allow designers to combine numerous complex features into a single component, reducing the need for secondary machining or surface finishing operations.

Plastic Injection molding allows design freedom not easily matched by other traditional processes.  Performance Plastics’ augments the latest software tools including solid modeling, mold flow analysis and finite element analysis with an internally developed iterative tool design approach to deliver complex geometries and densities superior to most other operations.

Our tooling modification process results in best in class part tolerances, particularly useful in molding mission critical parts where dimensional attributes need to be extremely precise.  We use this approach to produce net shape molded parts of exceptional quality, eliminating or significantly reducing secondary matching operations resulting in material and process cost savings.

Performance Plastics, located in Cincinnati, OH has over 30 years’ experience in molding tight tolerance advanced plastics such as Fluoropolymers (FEP/PFA Torlon, Ryton plastic, Peek & Ultem) for many industries.  We have developed proprietary processes enabling injection molding of parts that are thin walled, with tight dimensional tolerances, and complex geometries.

For more information and solutions, please contact Rich Reed, Vice President of Sales & Marketing at 513-321-8404 or email [email protected].

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