Types of Plastics used in the Semiconductor Industry

August 23, 2022  |  , , , ,

Precision and purity are key in the semiconductor industry.  Plastics help maintain high standards of precision and purity during semiconductor production, ensuring that less time and resources are wasted and that electronics function properly.

Since plastics are typically insulators, they may seem an unlikely material for use in semiconductor / electrical applications. However, in recent years, the composition of some plastic materials has been adapted to make these plastic materials behave as conductors or semi-conductors as opposed to insulators.

The semiconductor industry requires components that are manufactured from materials having a combination of heat resistance, conductivity, insulating, and shielding properties. All these properties are exhibited by high performance plastics. They are ideal materials with which to produce end products, as well as parts in the processing equipment used to manufacture semiconductors.

High performance plastics such as Fluorinated Ethylene Propylene (FEP), Polyether Ether Ketone (PEEK), and Polytetrafluoroethylene (PTFE), are characterized by their exceptional properties in different areas. High performance plastics are largely used where highest demands are placed on thermal or chemical resistance or product mechanics.

  • FEP – Fluorinatedethylenepropylene is a copolymer of hexafluoropropylene and   tetrafluoroetheylene;   boosts chemical resistance and useful low friction properties, and is  easily formable.  FEP is soft, slightly flexible, possesses a lower melting point of 260°C and is highly transparent and resistant to sunlight.  It is vastly superior in some coating applications involving exposure to detergents.

 

  • PEEK – Poly Ether Ketone  is a semicrystalline thermoplastic with exceptional high temperature performance, mechanical strength, and chemical resistance. It is capable of maintaining its stiffness at high temperatures and is suitable for continuous use up to 260°C (480°F). In addition, PEEK does not undergo hydrolysis and can be used for significantly long periods of time in areas where steam or water is common.

 

  • PTFE – Polytetrafluoroethylene is a tough, flexible, non-resilient material of average tensile strength with great thermal properties and excellent resistance to chemicals and passage of electric current. The coefficient of friction is unusually low and believed to be lower than any other solids. PTFE is an outstanding insulator over a wide range of temperatures and frequency.

Performance Plastics are specialists in high performance plastics engineering for the semiconductor industry. We partner with our customers to offer solutions to some of the most challenging applications.  For more information, please contact Rich Reed, Vice President of Sales & Marketing at 513.321.8404 or email [email protected].

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PEEK® Use in Medical Applications

August 16, 2022  |  , , ,
Thermoplastic medical spinal implant component, precision thermoplastic medical check valve, non-contaminating Thermoplastic medical valve component, precision thermoplasticmedical spinal implant component, non-contaminating medical spinal implant component

High Precision, PEEK, Thermoplastic Medical Spinal Implant Component

PEEK® is an organic thermoplastic polymer that offers excellent mechanical and chemical resistance properties because of its chemical make-up.  PEEK® is short for polyether ether ketone, which means it’s a member of the polyaryletherketone family. These polymers are notable for their phenylene rings and oxygen bridges, which result in resilience, durability and strength.

PEEK® is great for medical applications because it is one of the few high-performance polymers that is a bio-material – it is highly resistant to radiation which allows for easy sterilization.

  • Biocompatibility – PEEK® is a proven biomaterial, which means it is considered safe for use with in vivo applications. PEEK® shows no signs of cytotoxicity, genotoxicity, or immunogenetics.  The material has been successfully in use for over 20 years.
  • A favorable flexural modulus – Compared to metals such as titanium, stainless steel and other metal biomaterials, PEEK® is much more flexible. It behaves much more like bone in how it flexes and bears weight.  It does not cause stress shielding in nearby bone.
  • Pure radiolucency – PEEK® renders transparent on X-rays, CT and MRI scans – which makes it easy for surgical teams to track the positioning of implants and detect complications.

Many medical device manufacturers now use PEEK® as a way to improve the biocompatibility of load bearing implants.  PEEK® is increasingly becoming the new standard biomaterial across a range of medical, orthopedic, and dental applications.

Performance Plastics’ team of experienced engineers possess the expertise to design and manufacture technically challenging projects and offer complex solutions within the medical industry.

For more information on how Performance Plastics can assist in your material selection challenges, please contact Rich Reed, VP Sales & Marketing at 513.321.8404 or [email protected].

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The real cost of making an injection mold

August 9, 2022  |  , , , ,

When starting to produce a new product, it’s important to decide on the type of process you will use for the manufacturing process.  While injection molding is a very cost-effective process, the initial startup cost of the mold is often a barrier of entry.

Injection molding is a manufacturing process that is very efficient for producing parts in large volume.  It is typically used in the mass production process where the same part is being created in the thousands or even millions.

Upfront costs tend to be very high due to the design, testing, and tooling requirements.  If you are going to produce parts in high volumes, you want to make sure you get the design correct the first time. So, what are the costs associated with producing an injection mold?

  • Choice of Resin

One of the biggest factors that effect the price of the plastic injection molding process is the type of plastic resin used in manufacturing.  The choice of material will change the price based on color, compounding, and additives.  The most abrasive or corrosive the material, the most expensive the mold.

  • Complexity

The more intricate the component, the more difficult it is to design the manufacturing process.  Part complexity, tolerances, number of undercuts as well as surface finish all effect the cost.

  • Size

The size of the component also drives the price.  Larger parts require larger, more expensive molds, as well as more material to manufacture.  Larger molds also take longer to make, which increases the costs.

  • Mold Material

The material the mold is made from significantly impacts the price.  Short production molds are usually made from less expensive materials such as aluminum.  Long production molds require molds made from more durable and expensive materials like steel that will retain their features across several years.

  • Cavities

The higher the number of cavities – the higher the production costs.  Experienced mold designers can maximize cavitations to enhance productivity and lower costs even for the most intricate parts and components.

  • Mold Base

The base of the mold is the case used for holding all the components, inserts and cavities of the mold.  The price of the mold base depends on the type of steel and the size of the mold.

At Performance Plastics, we know how important it is to make the correct decisions when designing a mold.  We have a team of process experts who work with our clients to design and assist in the mold process. We focus on the total cost of ownership of a mold, production capacity, longevity, functionality, as well as initial capital expense.

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

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Meet our new Team Member – Lori Bragg – Senior Customer Service Coordinator

August 4, 2022  |  ,

Performance Plastics is pleased to announce the addition of our new Senior Customer Service Coordinator – Lori Bragg. Lori joins Performance Plastics with over 30 years’ experience, B.A. in Communications, and working with industry leading companies in Cincinnati, Ohio.

“Lori brings a wealth of experience in B2B manufacturing, inside sales, ERP processes, and customer service to our company” said Rich Reed, Vice President of Sales and Marketing, “The addition of Lori as a Senior Customer Service Coordinator is a representative of our continued commitment to provide our customers with the excellent customer service they have come to expect from PPL.  We are excited to have Lori join us and look forward to continued growth.”

Lori stated, “I look forward to helping Performance Plastics continue to meet our customers’ expectations by providing the highest level of service.”

Performance Plastics Ltd is a custom injection-molder of high-performance polymers for mission critical markets including Aerospace/Defense, Medical, and Precision Industrial.

 

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Injection Molded PFA for Semicon Meets F-57 Requirements

August 2, 2022  |  , , ,

At Performance Plastics, we hold the quality of our products to the highest standards. We know that quality is critical for our customers, so we go above and beyond to make sure our customers products are no less than ideal.

Manufacturing quality products is key to maintaining long term relationships with our customers. We take the time after injection molding a product to test the quality and to quantify compliance standards. This extra time assures that we are meeting all the specifications of our customers’ products.  To this end, we maintain SEMI F57 compliance for our customers PFA (Perfluoroalkoxy) and PTFE (polytetrafluoroethylene) injection molded products.

SEMI F57 compliance is a specification for polymer materials and components used in ultrapure water and liquid chemical distribution systems. The SEMI F57 standard requires fluid-component manufacturers to follow best practices in material science and not contaminate UHP processes with extractable ions, metallics or total organic carbon (TOC). The standard also covers surface roughness, particle contribution, metallic contamination, and reliability testing.

SEMI F57 Standards ensure compliance as they identify permissible limits for seven different aqueous leachable anions: bromide, chloride, fluoride, nitrate, nitrite, phosphate and sulfate.  Additionally, the standards measure for elevated levels of total organic carbon (TOC) which can have negative effect on silicon oxidation.

In order to ensure that we maintain SEMI F57 compliance, we have added new, additional quality testing steps. The steps occur during the molding, cleaning, drying and packaging processes. These quality tests are crucial – they certify that each product injection molded by Performance Plastics follows the SEMI F57 standards and will not contaminate ultrapure water and liquid chemical distribution systems.

For more information on how Performance Plastics can help your injection molded PFA or PTFE product achieve SEMI F57 compliance, contact Rich Reed our Vice President of Sales and Marketing, at (513) 321-8404 or [email protected].

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