Performance Plastics – Factors that Determine Injection Mold ROI

May 25, 2023  |  ,

Injection molds are one of the most significant investments a manufacturer can make.  The lifespan of the injection mold depends on several factors; the design and construction of the mold, the type of material being molded, the operating conditions, and the maintenance practices employed.  Generally, high-quality molds are built to be durable and last for a significant period.  Below are some factors that affect the longevity of injection molds:

  • Operating Conditions – The conditions in which your injection mold operates have a corresponding effect on the lifespan of your mold. Will the mold be used in dirty or harsh environmental conditions?  Or is it run in a clean, sanitary environment? Dirt can take a toll on your mold.
  • Time between production runs – In general, the less time between runs the shorter the lifespan of your mold will be. The result of less time between runs is that molds may be less likely to get full mold maintenance between each cycle.
  • Cycle times – Longer, slower cycle times can be less taxing on your molds, which in turn may help them last longer. The length of your cycle time is largely dependent on elements of your design, including wall thickness, as well as design complexity.
  • Injection mold material – The materials used to create your mold will also play a role in its longevity. Aluminum molds, for instance, won’t last as long as their steel counterparts. The materials being molded also play a role in longevity, as some materials will be harder on molds than others.

It’s important to mention that the lifespan of an injection mold is not solely determined by the number of cycles but also by the overall condition and functionality of the mold.  Factors such as wear, damage, and changes in the molding material or production requirements can necessitate repairs.

Performance Plastics are experts in precision injection molding.  We have developed proprietary tooling, unique metallurgy equipment, and processes that produce custom-molded plastics such as fluoropolymers, Ultem®, PEEK, and Torlon®.  We leverage our high-performance polymer expertise and technology to develop thermoplastic compounds and techniques to maximize your mold and provide the best ROI on your mold investment.

 

/by

Torlon for Precision Industrial Applications

May 18, 2023  |  , , ,

Torlon is a high-performance polymer that is often used in precision industrial applications due to its exceptional mechanical and thermal properties. It is a brand name for polyamide-imide (PAI), a thermoplastic material that exhibits excellent strength, stiffness, and dimensional stability.

Here are some key characteristics and advantages of Torlon in precision industrial applications:

  1. High Strength and Stiffness: Torlon has a high strength-to-weight ratio and exceptional rigidity, making it suitable for applications that require structural integrity and resistance to deformation under heavy loads.
  2. Dimensional Stability: Torlon maintains its dimensional stability even under elevated temperatures, which is crucial in precision applications where tight tolerances and accurate fit are required. It has a low coefficient of thermal expansion, reducing the risk of dimensional changes due to temperature fluctuations.
  3. Chemical Resistance: Torlon is highly resistant to a wide range of chemicals, including acids, solvents, fuels, and oils. This chemical resistance makes it suitable for applications in chemical processing, oil and gas, and other industries where exposure to corrosive substances is a concern.
  4. High-Temperature Resistance: Torlon retains its mechanical properties at elevated temperatures, with a glass transition temperature (Tg) of approximately 280°C (536°F) and a melting point of around 310°C (590°F). This thermal stability allows it to perform reliably in high-temperature environments.
  5. Low Friction and Wear Resistance: Torlon exhibits excellent tribological properties, including low friction and wear resistance. This makes it suitable for applications that involve sliding or rotating components, such as bearings, bushings, and wear pads.
  6. Electrical Insulation: Torlon is an excellent electrical insulator, offering high dielectric strength and low electrical conductivity. It is often used in electrical and electronic components where insulation and electrical performance are critical.
  7. Machinability: Torlon is known for its machinability, allowing it to produce complex shapes and precise components. It can be easily machined using conventional machining techniques, including milling, turning, drilling, and grinding.

Due to its exceptional properties, Torlon is commonly found in industries such as aerospace, automotive, electronics, oil and gas, chemical processing, and various other high-performance applications that demand precision, reliability, and durability.

For more information on Torlon or how a high-performance polymers can benefit your application, please contact Rich Reed, Vice President of Sales and Marketing at rreed@performanceplastics.com or visit our website at www.performanceplastics.com.

/by

Gain an edge with EnduroSharp® Scraper Blades

May 9, 2023  |  , ,

When using a tool for maintenance, it is important to use the right tool to perform the task the right way.  Using the incorrect tool wastes time, reduces efficiency, and puts the maintainer at risk of injury. Take for example a tool as basic as a scraper blade.  Not all scraper blades are made of the same material and provide the same functionality.  Some of the most common types of scraper blades on the market include Phenolic, Celcon®, Glass Filled Nylon, and Torlon®.

 

Phenolic Scraper Blades

Phenolic scraper blades come in assorted shapes, colors, and sizes.  Phenolic scrapers are commonly used for removing sealants, adhesives, stickers, labels, grime, and more.  Phenolic materials are the result of polymerization between layers of paper, canvas, linen, or glass cloth impregnated with a synthetic thermosetting resin.  It offers high resistance to flexing but does not offer the ability to be resharpened.  It will curl, peel and melt when attempting to resharpen.  Additionally, Phenolic may cause irritation to the skin, eyes, nose throat, and nervous system, so it is not ideal for use in incremental or heated material removal.

 

Celcon® Plastic Scraper Blades

Celcon® plastic scraper blades are currently approved by several MROs and are made of semi-crystalline thermoplastics that offer high tensile strength, stiffness, and toughness and may retain a sharp edge.  They are resistant to hot water and some solvents and are useful for sealant application, removal, and paint removal.  They are not, however, useful with newer aviation adhesives, or high-heat applications as they melt easily.  Celcon® dust may cause irritation in the upper respiratory tract when used at normal processing temperatures.

 

 

Glass-Filled NylonScraperBlades

Glass-filled nylon scraper blades are thermal polymers that hold a very sharp and hard edge.  It is far less likely to mar surfaces, but it is not categorized as non-marring.  Can sometimes often be reshaped, but edges tend to wear when prying.  Can not be re-sharpened. Resists chemicals and solvents with minimal degradation.  While adding glass to the nylon makes it substantially stronger, with superior tensile strength it is also substantially more brittle, abrasive, and heavier.

 

Torlon Scarper Blades

Torlon® scraper blades hold a superior edge, remove unwanted materials, and protect the underlying substrates.  Torlon® is a non-marring, high-strength, high-temperature polymer and is cured to produce a thermoset polymer.  As a thermoset, it is resharpenable, lightweight, chemically resistant, and safe for people under normal conditions.

EnduroSharp® offers a full line of Torlon® Aircraft Maintenance Tools that make the removal of sealants and adhesives more efficient.

For more information on the new EnduroSharp® Gap Blade & Scraper Blade kit, or any of our EnduroSharp® product lines, please contact Aileen Crass at acrass@performanceplastics.com or visit our website at www.performanceplastics.com/endurosharp.

 

 

 

/by

Plastics Support Sustainability

May 4, 2023  |  , ,

Strong, lightweight plastics enable us to live better while contributing to sustainability in many ways—all which stem from plastics’ ability to help us do more with less.

Plastics help us protect the environment by reducing waste, lowering greenhouse gas emissions, and saving energy at home, at work, and on the road. Plastic packaging helps to dramatically extend the shelf life of products while allowing us to ship more with less packaging material—reducing both product and packaging waste.

Plastics have a great environmental profile.  Only 4% of the world’s oil production is used for plastics and it takes much less energy to produce compared to other materials.  Plastics are durable, lightweight, and adaptable, now being used in projects that used to require metal materials.

Plastic adhesives, sealants, tools, and other building products are making our lives significantly more energy efficient while reducing costs. Plastics are building blocks of many value chains including healthcare, aviation, packaging, and increasingly the recycling industry. Sustainable plastic manufacturing conducts business in a way that drives value for society, the environment, and industry.

High-Performance plastics offer superior product quality in terms of durability, reusability, and recyclable quantities.  They are used in a wide range of multi-use applications and durable applications and are frequently used to replace other materials such as metal, wood, and glass.

 

 

/by

Product Spotlight – EnduroSharp® Gap Blade & Scraper Blade Kit with Pneumatic Tool

April 4, 2023  |  , ,

EnduroSharp® has changed the way aerospace maintenance professionals remove sealants and adhesives from substrates and fasteners.

After receiving feedback from aircraft professionals,  EnduroSharp® has combined two of our most popular kits into one consolidated kit.  This kit offers the full selection of the EnduroSharp® gap blades, and EnduroSharp® scraper blades, packaged in one convenient carrying case.  We even included the sharper in the kit, so our maintainers would have all the tools they need in one handy case!

Traditionally, aerospace maintainers removed adhesives and sealants using tools that weren’t designed for the job.  Patented EnduroSharp® Torlon® aircraft maintenance tools were specifically designed for this task.  EnduroSharp® Tools are non-metallic scraper tools designed specifically to remove silicone, sealants, adhesives, and coatings.

Performance Plastics is a custom precision injection molder of high-performance, tight-tolerance thermoplastic components. We specialize in geometrically complex precision parts that consist of chemically inert materials. Our expertise led to the development of our patented EnduroSharp® line of Aircraft Maintenance Tools.

For more information on the new EnduroSharp® Gap Blade & Scraper Blade kit, or any of our EnduroSharp® product lines, please contact Aileen Crass at acrass@performanceplastics.com or visit our website at www.performanceplastics.com.

 

 

/by

Why Use a High-Performance Plastic for your Gasket?

March 28, 2023  |  , , ,

A high-performance plastic is a resin that exhibits characteristics that make it a viable alternative to metals for use in industrial applications.  Characteristics include strength & durability, temperature resistance, electrical properties, lightweight, and versatility.  Overall, high-performance plastics can be custom designed to meet specific performance criteria and offer a wide range of benefits.

A gasket is a mechanical seal that fills the space between two or more mating surfaces to prevent leakage from or into joined objects under compression.  They extend the lifespan of moving parts by protecting against rubbing or friction.  Today, high-performance plastic gaskets are used as an alternative to metal gaskets as they offer great durability and corrosion resistance.  They are also lightweight, have low friction, and have good sealing and insulation properties.

The benefits of using a gasket made of high-performance plastics include:

  • Improved functionality and performance
  • Improved resistance to many chemicals
  • Improvement in vibration
  • Improved handling of temperature fluctuation
  • Improved impact resistance

High-performance plastic gaskets can be custom designed to meet specific performance criteria and offer a wide range of benefits depending on the application.

Performance Plastics has over 40 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 on high-performance plastic gaskets or other Performance Plastics’ services, please contact Rich Reed, Vice President of Sales & Marketing at 440-785-7122.

 

/by

Performance Plastics Experience in Material Knowledge for Gaskets, Seals, and Poppets

March 16, 2023  |  , , , ,

Gaskets, seals, and poppets are key components of industrial applications used to seal joints, limit vibration, and prevent leaks.  They serve critical functions, so it is essential to choose the correct material for the application.  Performance Plastics has a thorough understanding of high-performance thermoplastics including PEEK, PFA, FEP, Torlon, and Ultem to create reliable, better sealing, longer wearing, and more cost-efficient components.

When choosing a material, there are several factors to keep in mind to ensure the material is correct for the application.

  • Temperature – material must withstand the entire design temperature range.
  • Pressure – material must withstand the entire pressure range.
  • Corrosion Resistance – material should not corrode when it encounters fluids or by environmental exposure.
  • Product Standards
  • Industry Standards

The materials need to have good flexibility, low density, and high tensile strength.  It also needs to have resistance to chemicals, internal pressure, durability, and adhesion with itself and the surfaces they touch.

It is important to understand the requirements of the particular application before making a material selection.  Our CT scanning metrology service allows us to offer the best in advanced measurement science.  Gaskets, seals, and poppets must be measured to deliver and maintain their seals for an acceptable period against all the operational forces present.

Performance Plastics’ team of experienced engineers possess the expertise to design and manufacture technically challenging projects and offer complex solutions within any industry. With the ability to hold tight tolerances (+/- .001”) in injection molding operations, we are exceptionally well-equipped to serve the Oil & Gas, Fluid Management, and HVAC industries.

For more information on how Performance Plastics can assist in your material selection challenges, please contact Rich Reed, VP of Sales & Marketing at 513.321.8404 or rreed@performanceplastics.com

 

/by

What is a high-performance plastic?

February 28, 2023  |  , , ,

Plastics can be considered high-performance for a variety of reasons.  The specific application and the performance criteria are the most important.  Here are some characteristics that can contribute to a resin being classified as a high-performance plastic.

  1. Strength and durability: Many plastics are engineered (fiber reinforced) to be extremely strong and durable, with high tensile strength and resistance to wear, tear, and impact. This can make them well-suited for applications where mechanical stress is a concern. Examples include Torlon PAI and PEEK.
  2. Temperature resistance: Certain plastics are highly resistant to chemical corrosion or degradation, which can make them ideal for use in harsh environments or with corrosive substances. Examples include fluoropolymers such as PFA with a melting point of 581 degrees F.
  3. Electrical properties: Some plastics have excellent electrical insulation properties, making them ideal for use in electronics or other electrical applications. Examples include fluoropolymers such as FEP.
  4. Lightweight: Many plastics are lightweight, which can make them ideal for applications where weight is a concern, such as the aerospace, medical, or industrial markets.
  5. Versatility: Plastics can be easily injection molded into a wide variety of complex shapes and sizes, which can make them versatile and useful in a wide range of applications.

Overall, high-performance plastics can be custom designed to meet specific performance criteria and offer a wide range of benefits depending on the application.

For more information on high-performance plastics or other Performance Plastics services, please contact Rich Reed, Vice President of Sales & Marketing at rreed@performanceplastics.com or call 440-785-7122.

/by

Peek use in Semi-Conductor Applications – Wafer Manufacturing

February 7, 2023  |  , , ,

 

PEEK is short for polyether ether ketone. These polymers are notable for their phenylene rings and oxygen bridges, which result in resilience, durability, and strength.

Wafer manufacturing is a term used to describe the process of creating chips, otherwise known as integrated circuits, which are used in everyday devices.  You will find chips in everything from cars to military jets.  PEEK is great for semiconductor applications because of its outstanding combination of physical properties.

  • Longer Lifetime – CMP (chemical-mechanical positioning) rings made with PEEK can provide less downtime, and more throughput with up 2x wear resistance compared to other materials.
  • Potential Yield Enhancement – Low particle generation and higher purity, resulting in lower outgassing and extractives that may lead to yield improvements
  • Faster Process – PEEK endures proceseess with up to 260° and harsh chemicals, which allos for faster processing and less cooling time.

Semiconductor equipment manufacturers use PEEK screws and fasteners in wet benches. Chip manufacturers use hydrofluoric acid which is a corrosive chemical that can damage metals. Since PEEK is chemical-resistant, chip manufacturers are utilizing PEEK screws. These screws are used in the production of ICU’s since they are a high-purity material and possess low-outgas properties. PEEK is also used to manufacture manifolds for semiconductor production equipment.

Performance Plastics’ team of experienced engineers possess the expertise to design and manufacture technically challenging projects and offer complex solutions within the semiconductor 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 rreed@performanceplastics.com.

 

https://youtu.be/XRmbryDk6WQ

/by

Does your part need Flexibility & Strength – Consider Nylon®

January 26, 2023  |  , , ,

Nylon® is a synthetic thermoplastic polyamide that is known for its strength, temperature resilience, and chemical compatibility. It has been proven to be a lightweight, heavy-duty industrial engineering plastic replacement for metals that are resistant to both heat and corrosive chemicals.

Nylon® is a great material for parts that undergo flexure and bending.  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 parts that need to stand up to high levels of motion and wear. Performance Plastics offers expertise in developing Nylon® resin formulations and combinations with other polymers such as glass, carbon, and mineral-reinforced versions.  For example, Minlon®, a 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 aerospace applications.

Performance Plastics has seen Nylon®’s applications grow to include a range of applications 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, material, and processing costs have led many to opt for various Nylon® formulations instead. Performance Plastics can use Nylon® to offer a combination of physical strength, wear resistance, self-lubrication, and high cost-effectiveness.

Choosing the optimal Nylon® resin for an 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 part 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 deliver 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 RReed@performanceplastics.com.

/by