Performance Plastics leverages Industrial CT Scanning for Optimal Results

November 17, 2023  |  , ,

As you’re designing and manufacturing your next project, wouldn’t it be ideal if you could analyze all the existing 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) scans. This gives us the ability to measure all aspects of your part, without having to damage it.

Performance Plastics specializes in tight tolerance, high-performance polymers such as Peek, Torlon, FEP & PFA, and Ultem.  We leverage CT Industrial scanning to replicate parts made of other materials and improve their performance.

Industrial computed tomography (CT) scanning is a non-destructive testing (NDT) method that uses X-ray technology to produce detailed 3D images of the internal structure of objects. This technology is widely used across various industries due to its numerous benefits. Here are some key advantages of industrial CT scanning:

  1. Non-Destructive Testing (NDT): One of the primary benefits of industrial CT scanning is that it allows for non-destructive testing of objects. This means that the internal structures of components or products can be examined without causing any damage to the tested item. This is particularly important in industries where preserving the integrity of the object is crucial.
  2. High Resolution and Accuracy: Industrial CT scanners can produce high-resolution images with fine details, allowing for precise analysis of internal structures. This level of accuracy is especially valuable in industries where the quality and precision of components are critical, such as aerospace and automotive.
  3. Visualization of Internal Structures: CT scanning provides a three-dimensional visualization of the internal features of an object. This is particularly useful for inspecting complex geometries, assemblies, and multi-material components, allowing engineers and researchers to examine the internal structures in a comprehensive manner.
  4. Identification of Defects and Anomalies: Industrial CT scanning is highly effective in identifying defects, voids, cracks, and other anomalies within an object. This can be crucial for quality control and ensuring that products meet industry standards and safety requirements.
  5. Reduced Inspection Time: Compared to traditional methods of inspection, industrial CT scanning can significantly reduce inspection time. This is especially beneficial for industries where efficiency and rapid inspection are essential.
  6. Versatility: Industrial CT scanning can be applied to a wide range of materials, including metals, plastics, composites, and more. This versatility makes it a valuable tool across various industries, from manufacturing to medical research.
  7. Reverse Engineering: CT scanning can be used for reverse engineering applications, where the internal and external geometries of a component are captured digitally. This is useful for replicating or modifying existing components.
  8. Regulatory Compliance: In industries where compliance with safety and quality standards is essential, industrial CT scanning can help meet regulatory requirements by providing thorough and accurate inspections. In summary, industrial CT scanning offers a non-destructive, highly accurate, and versatile method for inspecting internal structures of objects, making it a valuable tool in various industries for quality control, research, and product development.

At Performance Plastics, we are experts in injection molding, specializing in high-performance plastics such as PEEK, Torlon, FEP & PFA, and Torlon for medical, aerospace, and industrial applications. Our proprietary tool design software, processes, and equipment enable us to injection mold components having complex geometries made from challenging ultra, high-performance thermoplastic materials, and reinforced compounds.

For more information on Performance Plastic’s capabilities, please contact Rich Reed, Vice President of Sales, and Marketing at 513.321.8404 or email at [email protected].

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The Importance of FEP/PFA for the Energy Storage Function of Batteries

November 9, 2023  |  , ,

Fluorinated ethylene propylene (FEP) and perfluoroalkoxy (PFA) are fluoropolymer materials that are often used in the construction of certain components in batteries, particularly as insulating materials. While they may not directly store energy in batteries, they play a crucial role in enhancing the safety, efficiency, and performance of battery systems. Here’s why FEP/PFA plastics are important for the energy storage function of batteries:

 

  1. Chemical Resistance: FEP and PFA plastics are highly chemically resistant, which is crucial in battery applications. They can withstand exposure to various corrosive electrolytes and chemicals found within batteries without degrading or reacting. This resistance helps ensure the long-term stability and integrity of the battery components, leading to improved battery durability and lifespan.
  2. Thermal Stability: FEP and PFA materials have excellent thermal stability and can withstand a wide range of temperatures, from extremely cold to very hot conditions. This property is essential for batteries, as they can operate in environments with varying temperature conditions. Maintaining thermal stability helps to prevent short circuits, leakage, and overall performance issues.
  3. Dielectric Properties: Both FEP and PFA injection molded parts are excellent electrical insulators. They have a low dielectric constant and low dissipation factor, meaning they have the ability to insulate and isolate electrical components in batteries effectively. This is vital for preventing short circuits and ensuring the safe operation of the battery.
  4. Low Permeability: FEP and PFA plastics have low gas and liquid permeability, which is essential for battery separators. The separators in batteries are critical for preventing direct contact between the positive and negative electrodes, while still allowing the passage of ions. Low permeability materials help maintain this separation, preventing electrolyte leakage and maintaining the battery’s overall performance.
  5. Mechanical Strength: FEP and PFA injection molded materials are durable and mechanically robust. They can withstand mechanical stresses and pressure changes that batteries may experience during manufacturing, assembly, and use. This strength is particularly important for maintaining the integrity of battery components and preventing damage.
  6. Non-reactive Nature: FEP and PFA are non-reactive with most substances, which is essential for ensuring the purity of the battery components. They do not react with the electrolyte or other battery materials, helping to maintain the chemical stability of the battery system.

While injection molded FEP and PFA plastics do not store energy in batteries themselves, they are crucial components for ensuring the safe and efficient operation of battery systems. Their chemical resistance, thermal stability, dielectric properties, low permeability, mechanical strength, and non-reactive nature all contribute to the overall performance, safety, and longevity of energy storage systems, making them indispensable for the function of batteries in various applications. For more information on FEP and PFA plastics for batteries, please call Rich Reed, Vice President of Sales and Marketing at 440-785-7122.

 

 

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Fluoropolymers are a great choice for Challenging Environments

October 26, 2023  |  , ,

Fluoropolymers are indeed an excellent choice for parts that must perform in challenging environments. These polymers, which include materials like PTFE (polytetrafluoroethylene), FEP (fluorinated ethylene propylene), and PFA (perfluoroalkoxy), offer a range of unique properties that make them ideal for such applications:

  1. Chemical Resistance: Fluoropolymers are highly resistant to a wide range of corrosive chemicals, acids, and bases. This makes them suitable for use in environments where other materials would quickly deteriorate or corrode.
  2. Temperature Resistance: These polymers can withstand extreme temperatures, both high and low. PTFE, for example, can handle temperatures as low as -200°C and as high as 260°C, making it ideal for applications in harsh temperature conditions.
  3. Non-Stick Properties: Fluoropolymers have excellent non-stick properties, which means they do not easily adhere to other materials. This is why they are often used in cookware coatings, but it’s also valuable in industrial applications where materials need to slide or not adhere to surfaces.
  4. Electrical Insulation: They have good electrical insulation properties, which is important in applications where electrical conductivity could cause problems.
  5. UV Resistance: Many fluoropolymers are highly resistant to ultraviolet (UV) radiation, making them suitable for outdoor applications.
  6. Low Friction Coefficient: These materials have a low coefficient of friction, which means they can reduce wear and tear in moving parts and machinery.
  7. Biocompatibility: Some fluoropolymers are biocompatible, making them suitable for use in medical and pharmaceutical applications.

Fluoropolymers find applications in various industries, including chemical processing, electronics, aerospace, and automotive, where they are exposed to aggressive chemicals, extreme temperatures, and other challenging conditions. Their durability, resistance, and performance characteristics make them an excellent choice for parts and components in these demanding environments.

For more information on how Performance Plastics can help you with your material choice in challenging environments, please contact Rich Reed, Vice President of Sales and Marketing at [email protected]

 

 

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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.

 

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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

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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

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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.

 

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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.

 

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Performance Plastics – USP Class VI Medical Compliance

June 29, 2023  |  , ,

In order to ensure the safety of medical devices, USP Class VI testing is required.  Developed by the United States Pharmacopeia, the Class VI test is a specific test conducted on medical devices to assess their biocompatibility.  It is designed to evaluate the potential adverse biological effects of the materials used in a medical device when they come into contact with living tissues or bodily fluids. Performance Plastics is proud to announce we have passed the test – we now offer material and process expertise.

The USP Class VI test is particularly important for medical devices that directly or indirectly interact with the human body, such as implants, surgical instruments, catheters, and tubing. The test helps to ensure that these devices are safe and do not cause harmful reactions or toxicity when used in clinical settings.

Here are a few key reasons why the USP Class VI test is conducted on medical devices:

  1. Patient Safety: The primary objective of the USP Class VI test is to ensure patient safety. By assessing the biocompatibility of the materials used in medical devices, it helps identify any potential risks or adverse reactions that may occur when the device is used in the human body.
  2. Regulatory Compliance: Compliance with regulatory standards is a crucial aspect of the medical device industry. Many regulatory bodies, including the U.S. Food and Drug Administration (FDA), require medical device manufacturers to demonstrate the biocompatibility of their products. Conducting the USP Class VI test helps meet these regulatory requirements.
  3. Material Selection: The USP Class VI test aids in material selection for medical devices. It helps manufacturers evaluate different materials and determine which ones are the most suitable in terms of biocompatibility. This allows them to make informed decisions about the materials used in their devices, minimizing the risk of adverse reactions.
  4. Product Development and Improvement: The test is also valuable during the product development and improvement stages. By identifying any potential biocompatibility issues early on, manufacturers can modify or optimize their device design or materials to enhance safety and efficacy.
  5. Industry Standard: The USP guidelines are widely recognized and accepted within the medical device industry. Conducting the USP Class VI test demonstrates a commitment to quality and safety, providing confidence to healthcare professionals, regulatory bodies, and end-users.

It’s worth noting that the USP Class VI test is just one of several tests and evaluations conducted to assess the biocompatibility of medical devices. Other tests, such as cytotoxicity, sensitization, and irritation tests, may also be performed depending on the specific device and its intended use.

For more information on Class VI testing and how Performance Plastics can assist in certifying your medical device, please contact Rich Reed, Vice President of Sales & Marketing at [email protected], or visit our website at www.performanceplastics.com.

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Performance Plastics – How a mold flow analysis can save you time and money.

June 13, 2023  |  , ,

A Mold flow analysis is a software simulation that can show how resin will fill the mold during the injection molding process. By understanding material fill, injection mold designers can better position gates, anticipate where knit lines will appear, and locate difficult-to-fill spots in the mold.

The predictive process of mold flow analysis can uncover design issues, save resources, allow for preemptive correction, speed up overall cycle time, and present your business with an abundance of benefits. Mold flow analysis is essential to ensure that a mold can produce the strongest and most consistent parts.

Here are our top six reasons why you should always perform a mold flow analysis:

  1. Optimization of Design

Without the investment of tooling or molding, all the what-if questions can be addressed ahead of time. Mold flow analysis can point out many concerns or production factors, including:

  • Material selection issues
  • Thickness/thinness problems
  • Structural concerns
  • Residual or structural stress issues
  • Filling concerns
  1. Quick & Immediate Decisions

With mold flow analyses, you can make immediate, informed decisions. These decisions can impact multiple areas of the process including:

  • Product design
  • Material and process selection
  • Tooling
  1. Optimization of Injection Molds and Tooling

You will have all the information upfront to make the most optimal choices in injection molds and tooling to create the perfect product. Mold flow analysis can show you everything you need:

  • The optimal gate locations
  • Balanced filling and packing
  • Cavity layout
  • The best cooling layouts
  • Structural and thermal analyses for tool life
  1. Trying Different Materials

You’re able to test out different materials and designs without building any prototype parts or tools. You can get virtual parts with a simulation as well, so you can have a full process simulation with minimal upfront investment.

  1. Optimize Overall Cycle Time

Mold flow analyses can optimize your overall cycle time by up to 10-30%. That reduction percentage on just one part can cancel out the cost of a complete flow analysis of multiple molded parts!

  1. Specification

Plastic parts can be optimized for exact machine specification, cycle time, cooling, DOE, and more, without reducing production time or putting any tools on molding machines; this can help improve your bottom-line profit.

The predictive process of mold flow analysis can uncover design issues, save resources, provide for preemptive correction, speed up overall cycle time, and present your business with an abundance of benefits.

Performance Plastics provides mold flow analysis to help your business improve manufacturing processes by saving time and money. For more information on how mold flow analysis can provide simplicity and quality to products, please contact Rich Reed, Vice President of Sales & Marketing at [email protected], or visit our website at www.performanceplastics.com.

 

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