The Benefits of FEP and PFA Conductive Polymers

September 28, 2023  |  ,

Conductive polymers such as FEP and PFA are a class of materials that exhibit electrical conductivity while maintaining the mechanical properties and processability of traditional polymers. These materials have garnered significant attention and research interest due to their unique combination of properties, which offer a wide range of potential applications. Here are some of the benefits of conductive polymers:

  1. Electrical Conductivity: Conductive polymers can conduct electricity, making them suitable for various electronic and electrical applications. Unlike traditional insulating polymers, which do not conduct electricity, conductive polymers can carry electrical currents.
  2. Lightweight and Flexible: Conductive polymers are lightweight and flexible, which makes them ideal for applications where traditional conductive materials like metals would be impractical due to their weight or lack of flexibility. This property is particularly advantageous in wearable electronics, flexible displays, and flexible sensors.
  3. Processability: Conductive polymers can be processed using conventional polymer processing techniques, such as injection molding. This ease of processing allows for the production of complex shapes and making them versatile materials for various applications.
  4. Corrosion Resistance: Unlike metals, conductive polymers are generally corrosion-resistant, making them suitable for use in harsh environments, such as marine or chemical processing applications.
  5. Biocompatibility: Some conductive polymers are biocompatible, which means they can be used in medical devices, implantable electronics, and tissue engineering applications without causing harm to living tissues.
  6. Low Cost: Conductive polymers are often more cost-effective than traditional conductive materials like metals or semiconductors. This cost advantage can make them attractive for large-scale applications.
  7. Energy Storage: Conductive polymers are used in energy storage devices, such as supercapacitors and batteries, due to their ability to store and release electrical energy efficiently.
  8. Sensors and Actuators: They are used in various sensor and actuator applications, including chemical sensors, gas sensors, strain sensors, and smart materials that can change shape or properties in response to electrical stimuli.

While conductive polymers offer many advantages, they also have some limitations, such as lower electrical conductivity compared to metals and sensitivity to environmental factors like moisture and oxygen.

For more information on electrically conductive materials and how Performance Plastics leverages their use, please contact Rich Reed, Vice President of Sales & Marketing at 440-785-7122 or [email protected]

 

/by

The Importance of Maintenance of Injection Molds

September 14, 2023  |  ,

Maintenance of injection molds is crucial in manufacturing plastic and metal parts. It plays a significant role in ensuring product quality, minimizing downtime, and extending the lifespan of the molds. Here are some key reasons highlighting the importance of maintenance of injection molds:

  1. Quality Assurance: Regular maintenance helps uphold the quality and consistency of the manufactured products. Any wear and tear on the mold can lead to defects in the final products, such as surface imperfections, warping, or dimensional inaccuracies.
  2. Cost Efficiency: Preventive maintenance is more cost-effective than corrective measures. Properly maintained molds are less likely to break down, reducing the need for costly repairs or replacements. This can lead to significant cost savings over time.
  3. Downtime Reduction: Mold breakdowns or failures can result in production downtime, which can be extremely costly for manufacturing facilities. Routine maintenance can help identify and address potential issues before they cause major disruptions in production.
  4. Longevity of Molds: Injection molds can be expensive to produce, so maximizing their lifespan is essential to get a return on investment. Regular maintenance can extend the life of molds, allowing them to be used for a more extended period.
  5. Consistent Cycle Times: Well-maintained molds operate more efficiently, leading to consistent cycle times. This ensures that production targets can be met without unexpected delays or variations in output.
  6. Productivity Improvement: Maintaining molds at optimal conditions can enhance productivity by reducing the likelihood of production defects, mold-related issues, and unplanned downtime. This, in turn, boosts overall efficiency.
  7. Safety Considerations: Molds that are in poor condition can pose safety risks to workers. Sharp edges, loose components, or damaged parts can lead to accidents. Regular maintenance helps identify and rectify potential safety hazards.
  8. Waste Reduction: When molds are not properly maintained, defective parts are likely to be produced. This can result in increased material waste, which is both environmentally and economically unfavorable.
  9. Customer Satisfaction: Consistency in product quality, thanks to well-maintained molds, leads to higher customer satisfaction. Satisfied customers are more likely to return and recommend your products to others.
  10. Compliance with Standards: In some industries, there are strict quality and safety standards that must be adhered to. Regular mold maintenance can help ensure compliance with these standards and prevent costly fines or legal issues.

In summary, maintenance of injection molds is critical for maintaining product quality, reducing costs, minimizing downtime, ensuring safety, and prolonging the life of molds. Investing in a proactive maintenance program is a smart strategy for any manufacturing operation that relies on injection molding processes.

For more information on how Performance Plastics maintains our molds and our manages our best practices, please contact Rich Reed, Vice President of Sales and Marketing at [email protected], or visit our website and www.performanceplastics.com.

 

/by

Process Monitoring is Crucial in Tight Tolerance HPM Plastic Injection

September 7, 2023  |  , ,

Plastic Injection Molding HPM (high-performance material) parts with tight tolerances demand that processes are repeatable within established limits.  Performance Plastics utilizes best practices to eliminate process inefficiencies and unplanned maintenance, when working with materials such as Torlon (PAI), PEEK, Ultem (PEI) and FEP/PFA.  Simple processes must take place every shift to ensure that process and production are on target.

  • Process Validation

Process validation procedures must be completed prior to establishing process monitoring.  A validated process must run at complete cycle efficiency, producing little to no scrap for no less than 8 hours.  Evaluations and considerations must be analyzed whether a process can be repeated from one run to the next.

  • Process Installation Qualification – Making Sure Everything Works
  • Operational Qualification – Test, Test, and Test Again
  • Performance Qualification – Testing the actual Part.
  • Process Monitoring

Many companies fail to understand that a similar press or mold does not guarantee the tight tolerance processes will be repeated, especially when working with HPMs.  Each press must have its own process monitoring record, and sister molds need to be approached as completely different molds.

Areas that must be constantly monitored:

  • Fill Time
  • Peak Pressure
  • Part Weight
  • Cycle

Each value must have control limits and must be within the window established for these limits to control.

  • Basic Molding Fundamentals

The key to the HPM process consistency is the care and inspection of molds before each job.

  • Molds are cleaned and inspected.
  • Nozzles are inspected for blowback.
  • Hot runner point temperatures are verified.
  • Water is verified at the beginning of each run.

Performance Plastics embraces best practices in order to provide our customers with the quality and repeatability required for HPM tight tolerance medical, aerospace, and industrial parts.

For more information on how Performance Plastics manages our best practices, please contact Rich Reed, Vice President of Sales and Marketing at [email protected], or visit our website and www.performanceplastics.com

/by

Performance Plastics – Resin Compounds in Aerospace Applications

August 24, 2023  |  ,

Resin compounds play a crucial role in various aerospace applications due to their lightweight, high-strength, and durable properties. They are commonly used in the aerospace industry for manufacturing components such as aircraft structures, interior components, propulsion systems, and more. Here are some key points about the use of resin compounds in aerospace applications:

  1. Composite Materials: Resin compounds are often used as matrix materials in composite structures. Composite materials are made by combining reinforcing fibers (such as carbon fibers, glass fibers, or aramid fibers) with a resin matrix. These materials provide a high strength-to-weight ratio, making them ideal for aerospace applications where weight savings are critical.
  2. Fiber Reinforced Polymers (FRP): In addition to carbon fibers, other types of fibers like glass and aramid are used in aerospace composites. Glass fiber reinforced polymers (GFRP) are used in applications that require good corrosion resistance, while aramid fiber reinforced polymers (AFRP) are known for their impact resistance.
  3. Thermosetting Resins: Epoxy resins are one of the most commonly used thermosetting resins in aerospace applications due to their excellent mechanical properties, high heat resistance, and low shrinkage during curing. They are often chosen for critical structural components.
  4. Thermoplastic Resins: Thermoplastic composites are gaining popularity in aerospace due to their improved impact resistance, damage tolerance, and recyclability. They can be reheated and reformed, allowing for potential repairs or reshaping of components.
  5. Adhesives and Bonding: Resin-based adhesives are used for bonding various components in aerospace manufacturing, including joining composite panels, attaching metal components, and creating strong bonds between dissimilar materials.
  6. Fire Resistance: Fire-resistant resins are essential for aerospace applications to ensure the safety of passengers and crew. Fire-resistant resins are often used in interior components, like cabin walls and flooring, to meet stringent safety standards.
  7. Repair and Maintenance: Resin-based materials are also used for repairing and maintaining aircraft and spacecraft structures. Composite repair patches and epoxy-based sealants can extend the life of aerospace components.
  8. Design Flexibility: Resin compounds offer design flexibility, allowing engineers to create complex shapes and optimized structures that might not be achievable with traditional materials.

It’s worth noting that the aerospace industry has stringent regulations and standards for the use of materials in aircraft and spacecraft. The choice of resin compound and its application must meet these requirements to ensure safety, reliability, and performance in various aerospace environments.

For more information on resin compounds and their uses in Aerospace Manufacturing, please contact Rich Reed, Vice President of Sales & Marketing at [email protected], or visit our website at www.performanceplastics.com.

/by

What You Don’t Know About FEP/PFA Injection Molding Is Costing You Money

August 24, 2023  |  

A fluoropolymer is one of the growing number of fluorocarbon-based polymers. They are widely used in healthcare applications due to their biocompatibility, lubricity, sterilizability, chemical inertness, thermal stability, barrier properties and high purity. However, when compared with other resins, they are significantly more expensive and require special techniques to injection mold due to their shear sensitivity, high melt temperatures, and fluorine outgassing when melted.

Although the best-known fluoropolymer, polytetrafluoroethylene (PTFE or Teflon®), has been on the market since the 1940s, newer resins have been developed to address specific injection molding niches. Perfluoroalkoxy polymer (PFA) and fluorinated ethylene-propylene (FEP plastic) are among the most recent additions to the list of fluoropolymer options.

PFA was developed in order to create a true melt-processable fluoropolymer. It provides the smoothest and least wettable finish of all of the fluoropolymers. Its optical transparency, chemical inertness, and overall flexibility have made it popular for use in lab equipment. It also has superior electrical properties, with dielectric strength that’s three to four times greater than PTFE can offer.

Like PFA, FEP is melt-processable and injection moldable. Its melting point of 260 °C (500 °F) is about 40 degrees lower than PFA’s.  It offers low friction and chemical inertness properties comparable to PTFE’s. However, it is completely transparent. Because FEP is highly resistant to sunlight, it is especially useful for molding parts that are subjected to weathering.

However, not all injection molders are equipped to work with fluoropolymers like PFA and FEP. Performance Plastics LTD. has developed a variety of tools and procedures to address the challenges involved in molding these materials. For example, our solution includes a hot runner system and mold designed to minimize the shear forces inherent in the injection molding process. We use proprietary metallurgy that’s highly resistant to fluorine gas corrosion, which helps extend the working life of the hot runner system, tooling and other components that make contact with the melted resin. We’ve also developed a direct-gating, multi-runner approach to tool design that eliminates the sprue and runner used in traditional injection molding. By eliminating the wasted material associated with the sprue and runner, Performance Plastics has been able to pass along material cost savings of from 20% to 40% by using these expensive resins more economically.

/by

Designing for Manufacturing using Plastic Injection Molding

August 17, 2023  |  , ,

Design for Manufacturing (DFM) is a crucial aspect of the plastic injection molding process. It involves optimizing the design of a plastic part to ensure that it can be easily and cost-effectively manufactured using injection molding techniques. Here are some key considerations and guidelines for DFM in plastic injection molding:

Part Geometry and Complexity:

  • Keep the part geometry simple and avoid intricate features that could complicate the molding process or require complex tooling.
  • Minimize the use of undercuts, sharp corners, and thin walls to prevent molding defects and challenges in ejection.

Draft Angle:

  • Incorporate draft angles (tapered surfaces) on vertical walls to facilitate easy ejection of the part from the mold.
  • A typical draft angle is around 1-2 degrees per side, but this may vary based on the material and part design.

Wall Thickness:

  • Maintain uniform wall thickness throughout the part to ensure proper flow of molten plastic and reduce the risk of sink marks, warping, or voids.
  • Avoid sudden transitions between thick and thin sections, as this can lead to molding defects.

Ribs and Bosses:

  • Use ribs to reinforce thin sections of the part and add structural integrity.
  • Design bosses (protruding features) with appropriate wall thickness and draft angles to ensure good mold filling and easy part ejection.

Corners and Fillets:

  • Incorporate rounded corners and generous fillet radii to distribute stress and prevent stress concentrations that could lead to part failure.

Material Selection:

  • Choose a suitable plastic material for the intended application, considering factors such as mechanical properties, chemical resistance, temperature stability, and more.

Gating and Venting:

  • Position the gate (entry point for molten plastic) in a location that minimizes aesthetic defects and ensures uniform filling.
  • Provide adequate venting to allow air and gases to escape during injection, preventing voids and trapped air.

Texture and Surface Finish:

  • Consider the desired texture or surface finish early in the design process, as this may impact mold design and material flow.
  • Textures can help hide imperfections and improve aesthetics.

Tolerances:

  • Specify realistic tolerances that are achievable through the injection molding process.
  • Avoid tight tolerances that could increase manufacturing costs and lead to rejects.

Moldability Analysis:

  • Conduct mold flow analysis using simulation software to identify potential issues and optimize the part design before production.
  • Address potential concerns such as weld lines, air traps, and flow imbalances.

Tooling Considerations:

  • Collaborate closely with the tooling manufacturer to ensure the mold design aligns with the part design and material properties.
  • Optimize the number and complexity of mold cavities based on production volume requirements.

Assembly and Post-Processing:

  • Design parts for easy assembly by incorporating features like snap fits, self-locating tabs, and mating surfaces.
  • Minimize the need for secondary operations or post-processing steps.

By following these design principles and collaborating with experienced injection molding professionals like Performance Plastics, you can create plastic parts that are well-suited for efficient and cost-effective manufacturing through the injection molding process.

For more information on Design for Manufacturing and its use, please contact Rich Reed, Vice President of Sales & Marketing at [email protected], or visit our website at www.performanceplastics.c

/by

Benefits of Reshoring Injection Molds in a Post-Covid Economy

August 10, 2023  |  ,

Reshoring

According to the American Manufacturing Resurgence Poll, 48% of CEOs have restored some or all of their operations.

Reshoring refers to the process of bringing back manufacturing or other business operations to the domestic country from overseas locations. Transferring molds from Asia back to the United States has been a huge topic post-Covid.  In a post-COVID environment, reshoring can offer several benefits, particularly in light of the disruptions and challenges that the pandemic exposed in global supply chains. Here are some potential benefits of reshoring in a post-COVID world:

  • Supply Chain Resilience: The COVID-19 pandemic highlighted vulnerabilities in global supply chains, as lockdowns, travel restrictions, and disruptions to transportation led to delays and shortages. Reshoring can help reduce dependence on distant suppliers and mitigate the risk of similar disruptions in the future, leading to greater supply chain
  • Reduced Lead Times: Shorter supply chains associated with reshoring can lead to reduced lead times, allowing companies to respond more quickly to changes in demand and market conditions. This agility is especially valuable in a rapidly changing post-pandemic business landscape.
  • Quality Control: When operations are brought closer to home, it becomes easier to implement and enforce stringent quality control This can lead to higher product quality, fewer defects, and improved customer satisfaction.
  • Innovation and Collaboration: Proximity to manufacturing operations fosters collaboration between different departments, such as design, engineering, and production. This can lead to increased innovation, as teams can work closely together to develop and refine products.
  • Trade Cost Savings: Reshoring can reduce or eliminate costs associated with international shipping, customs duties, and other trade-related expenses, potentially leading to cost savings for companies.
  • Risk Mitigation: Having production facilities in multiple geographic locations can diversify risks and reduce exposure to disruptions caused by localized events, such as natural disasters or geopolitical tensions.

It’s important to note that while reshoring offers various benefits, it may not be suitable for every industry or company. The decision to reshore should be based on a thorough analysis of factors such as cost, labor availability, skill sets, regulatory environment, market demand, and more. Reshoring is just one strategy that companies can consider as they adapt to the evolving global business landscape in the wake of the COVID-19 pandemic.

For more information on how Performance Plastics can assist in reshoring your mold, please contact Rich Reed, Vice President of Sales and Marketing at [email protected], or visit our website at www.performanceplastics.com.

 

/by

EnduroSharp® Surface Preparation Tools to achieve the best Adhesive Bond

August 3, 2023  |  ,

Torlon Sealant Removal Cutter

Using adhesives for connection technology has many benefits. It is cost-efficient, and fast, and allows homogeneous stress distribution between the bonded surfaces.

Adhesively bonded surfaces consist generally of two joined components and a layer of adhesive between them. The most important part of the bond is the adhesive itself, followed by the preparation process that precedes the application of the adhesive. The adhesive bonding process requires its own special process, which involves three main aspects: qualified methods/processes, trained operators, and dedicated tools.

The benefits of adhesive bonding include:

  • Expresses weight savings with the elimination of rivets or other stress concentrations
  • More evenly distributed stresses
  • Excellent fatigue resistance
  • Increased compliance with critical tolerances
  • Enables joining of dissimilar base materials.

Any professional who works with adhesives knows surface preparation is the most vital element of achieving high bond strength and optimizing durability and lifespan.  Different substrate materials require different types of preparation, but all must remove intermediate surfaces cleanly and thoroughly.

Patented EnduroSharp® Torlon® maintenance tools, exclusively from Performance Plastics, are the correct, dedicated tools for surface preparation.  They are non-metallic scraper tools that quickly and effectively remove silicone, sealants, adhesives, and coatings while keeping an effective edge and not damaging underlying materials.

 

Developed from Torlon® polyamide-imide, EnduroSharp tools hold a superior edge, are resharpenable, remove unwanted materials and protect expensive projects.

For more detailed information about the EnduroSharp® line of tools and how they can save you time and money in maintenance, please reach out to Rich Reed, Vice President of Sales and Marketing, at [email protected] or visit our website at www.performanceplastics.com/endurosharp.

 

/by

Expertise is critical for a Precision Injection Molding Project

July 20, 2023  |  , ,

Expertise plays a vital role in precision injection molding. Precision injection molding involves the production of high-quality, complex, and intricate plastic parts with tight tolerances. It requires specialized knowledge, skills, and experience to achieve consistent and accurate results.

Here are some reasons why expertise is critical in precision injection molding:

  1. Tooling Design: Expertise in precision injection molding includes a deep understanding of tooling design. This involves designing molds with precise cavities, gates, runners, and cooling systems to ensure optimal part quality and dimensional accuracy.
  2. Material Selection: Knowledge about different types of plastic materials and their properties is crucial. Experts can select the most suitable material based on the specific requirements of the part, such as strength, flexibility, heat resistance, or chemical resistance. This helps in achieving the desired functionality and durability.
  3. Process Optimization: Injection molding experts have in-depth knowledge of process parameters, such as temperature, pressure, and injection speed. They can optimize these parameters to ensure consistent part quality, minimize defects like warping or sink marks, and reduce cycle times.
  4. Troubleshooting: Even with careful planning, issues can arise during the injection molding process. Expertise allows for effective troubleshooting and problem-solving. Experienced professionals can identify and resolve issues like air traps, short shots, flash, or dimensional variations, ensuring that the final parts meet the required specifications.
  5. Quality Assurance: Precision injection molding demands stringent quality control. Experts can develop and implement robust inspection and testing protocols to verify part dimensions, surface finish, and other critical parameters. This helps in maintaining consistent quality and meeting customer expectations.
  6. Cost Optimization: Expertise in precision injection molding can help in optimizing costs. By fine-tuning the process, reducing scrap rates, and minimizing cycle times, experts can enhance efficiency and reduce overall production costs.

Precision injection molding requires a high level of expertise to achieve accurate and consistent results. Performance Plastics possesses the knowledge and experience of experts in areas such as tooling design, material selection, process optimization, troubleshooting, quality assurance, and cost optimization are crucial for producing high-quality plastic parts with tight tolerances.

For more information on how Performance Plastics can offer expertise on your next Precision Injection Molding project, please contact Rich Reed, Vice President of Sales & Marketing at [email protected] or visit our website at www.performanceplastics.com/capabilities.

 

/by

Introducing the new EnduroSharp® TSR Cutter

July 12, 2023  |  ,

Introducing the EnduroSharp® TSR Cutter, specifically designed for larger aircraft maintenance applications. Made from resharpenable Torlon®, the SR Cutter is the newest addition to the EnduroSharp® line of tools.

EnduroSharp® TSR Cutters are specially engineered to handle challenging tasks such as the removal of sealants and adhesives from aircraft wing fuel tanks and around fasteners like rivets, hi-loks, and bolts. Unlike competitors’ tools made from simple plastic, the EnduroSharp® TSR Cutter is crafted from resharpenable Torlon® PAI, allowing for multiple uses and extended durability.

The EnduroSharp® TSR Cutter is a Torlon® rotary cutting tool that effectively eliminates sealants, adhesives, and coatings without causing abrasion to underlying substrates, paints, primers, or metal surfaces. It achieves a thorough cleaning without the need for chemical solvents, thereby reducing chemical waste and minimizing exposure risks.

For more detailed information about the EnduroSharp® Torlon® TSR Cutter and how EnduroSharp® tools can save you time and money in aircraft maintenance, please reach out to Rich Reed, Vice President of Sales and Marketing, at [email protected] or visit our website at www.performanceplastics.com/endurosharp.

Equip yourself with the EnduroSharp® TSR Cutter and experience a cutting-edge solution for efficient and effective aircraft maintenance.

 

/by