Pexco Specializes in High-Performance Fluoropolymer Molding & Extrusion Technologies

August 1, 2024  |  , ,

Fluoropolymers are used in many industries, including aerospace, pharmaceutical, medical, and semi-conductors where they are used for seals, gaskets, bushings, bearings, hoses, tubing, wiring, even fiber optics cladding and semi-conductors. There are multiple ways to manufacture parts and components made from fluoropolymers, injection molding and profile extrusion are two of the most efficient.

What Are Fluoropolymers?

Fluoropolymers,as the name no doubt implies, are polymers that are based on bonding between fluorine and carbon. The first fluoropolymer was PTFE (polytetrafluoroethylene), which is perhaps better known by its trade name Teflon. Other common fluoropolymers include ETFE (ethylene tetrafluoroethylene), PFA (perfluoroalkoxy alkane), PVDF (polyvinylidene fluoride), PVF(perfluoralkoxy), FEP (fluorinated ethylene propylene), and ECTFE (ethylenechlorotrifluoroethylene).

Fluoropolymers are popular materials because of their properties which include resistance to high temperatures, chemical attacks, and electrical current. They are also low friction, non-toxic, exhibit minimal aging and leaching of chemicals. In addition, many fluoropolymers are biocompatible, making them ideal for medical applications.

  • Injection Molding: This process involves melting the fluoropolymer resin pellets andinjecting the molten material into a mold cavity under high pressure. Oncecooled and solidified, the part is ejected from the mold. Injection molding issuitable for producing intricate shapes with high precision and is commonlyused for smaller, complex parts.
  • Profile Extrusion: In this method, the fluoropolymer resin is melted and forced through a die that shapes it into a continuous profile of the desired cross-section. The profile is then cooled and cut to the desired lengths.Profile extrusion is often used for manufacturing longer, continuous shapes such as tubing, rods, and strips.

Both processes have their advantages depending on the specific requirements of the part, such as size, complexity, and production volume.

Working with fluoropolymers can be challenging, but not impossible.  Selection of the right polymer material for the application and consideration of processing parameters like tooling designare crucial for successful manufacturing. Materials like PFA and FEP are known for their melt-processability, making them suitable for the molding process.

Pexco’s specialization in high-performance fluoropolymer molding and extrusion technologies makes us a valuable partner for industries requiring components made from fluoropolymers. Our expertise in utilizing processes like injection molding and profile extrusion helps us meet specific requirements for parts interms of size, complexity, and production volume.

For more information on how Pexco can assist you with your next extrusion project, please visit our website at www.pexco.com, or contact our office at 513.321.8404.

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Pexco Offers Advanced Extrusion & Compression Techniques

July 25, 2024  |  , ,

Pexco utilizes advanced extrusion techniques encompassing arange of sophisticated manufacturing methods to produce profiles, tubes, and multi-layered products with specific properties and configurations. Here’s an overview of each technique:

 

 

Profile Extrusion

  • Definition: Profile extrusion involves extruding plastics such as ABS, TBE, PE, and PC into a continuous shape that can vary in complexity, from simple designs to intricate profiles with specific cross-sections.
  • Advanced Techniques:
    • Precision Control: Utilizing advanced die designand computer-controlled extrusion systems to achieve precise dimensionsand surface finishes.
    • Co-extrusion: Integrating multiple materials or layers during the extrusion process to impart desired properties such as color, texture, or functional attributes.
    • In-line Processing: Incorporating secondary operations such as cutting, punching, or coating directly into the extrusion line for enhanced productivity and versatility.
  • Applications: Profiles are used extensively in construction (window frames, decking), automotive (trim and seals), and consumer goods (furniture components, appliance trims).

Tube Extrusion:

  • Definition: Tube extrusion involves the extrusion of plastics such as HDPE, FEP/PFA, and ETFE to create hollow tubes of various diameters and wall thicknesses.
  • Advanced Techniques:
    • Micro extrusion: Producing very small diameter tubes with high precision, often used in medical devices (catheters, tubing for drug delivery).
    • Multi-layer Extrusion: Extruding tubes with multiple layers to achieve specific properties like barrier resistance or flexibility.
    • High-speed Extrusion: Implementing advanced cooling and handling systems to maintain dimensional stability and surface quality at high extrusion speeds.
  • Applications: Tubes find application in industries such as healthcare (medical tubing), industrial (piping and conduits), and food processing (packaging and conveying).

Co-Extrusion:

  • Definition: Co-extrusion involves extruding multiple layers of different materials such as PTFE, ABS and PE,  simultaneously to form a single continuous profile or tube.
  • Advanced Techniques:
    • Barrier Properties: Creating structures with enhanced barrier properties against gases, moisture, or UV radiation.
    • Functional Integration: Combining materials with different properties (e.g., stiffness, flexibility) within a single extruded product.
    • Multi-color Extrusion: Producing profiles or tubes with distinct color layers without secondary painting or coating processes.
    • Applications: Widely used in packaging (food packaging films, bottles), construction (multi-layer pipes), and automotive (multi-material trim components).

 

Tri-Extrusion and Crosshead Extrusion:

  • Tri-Extrusion:
    • Definition: Tri-extrusion involves the simultaneous extrusion of three different materials such as ABS, PC , and PP  layers to create complex profiles or tubes.
    • Applications: Enables the production of products requiring three distinct layers with specific performance characteristics, such as  weatherability, strength, and aesthetic appeal.
  • Crosshead Extrusion:
    • Definition: Crosshead extrusion is a technique used in cable and wire manufacturing to apply an additional layer of insulation or jacketing around a core conductor.
    • Advanced Techniques: Precise control over thethickness and uniformity of the extruded layer, ensuring electricalinsulation properties and mechanical protection.
    • Applications: Essential in the production of cables for telecommunications, automotive wiring harnesses, and industrial powercables.

Benefits and Applications:

  • Benefits: Advanced extrusion techniques offer benefits such as increased production efficiency, precise control over material properties, customization of products with multiple layers or profiles, and integration of functional features. Typical materials include PVC, HDPE, LDPE, and nylon.
  • Applications: These techniques are essential in various industries including automotive,  medical, packaging, and electronics, where they enable the creation of lightweight, durable, and high-performance components tailored to specific requirements.

 

Pexco specializes in advanced extrusion techniques such as profile extrusion, tube extrusion, co-extrusion, tri-extrusion, and crosshead extrusion.  These techniques play pivotal roles in modern manufacturing, facilitating the production of complex, multi-functional plastic products across a wide range of applications and industries.  We leverage years of expertise to bring your product to market – on time and on budget.

 

For more information on how Pexco can assist you with your next extrusion project, please visit our website at www.pexco.com,or contact our office at 513.321.8404.

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Solving Your Most Difficult Challenges – Custom Plastic Manufacturing Capabilities

July 18, 2024  |  , ,

At Pexco, our strength lies in our solution diversity.  From custom solutions to solving specific engineering challenges, our expertise guarantees outstanding results. Pexco has been helping our customers bring ideas to life for nearly half a century.

Pexco specializes in the manufacturing of extruded, injection, and compression molded plastic parts. We deliver customized manufacturing solutions to meet the specific needs of each customer.  These solutions can help companies of all sizes accelerate time-to-revenue, lower production costs, and establish a flexible, resilient, and scalable supply chain for custom manufacturing. Each of these methods has its strengths depending on the complexity, volume, and specific requirements of the item.  Below is a brief outline of each method, and their typical advantages:

Extrusion Molding:

Extrusion Molding is used to form plastic materials into a pre-defined shape. During the process, the material is melted and pushed through an extrusion molding machine, forming a long, tube-like shape or rod.  This is cooled and cut to the required specs.

  • Process: Plastic material is melted and pushed through a die to create a continuous profile.
  • Advantages: Suitable for producing continuous shapes with consistent cross-sections. It’s efficient for high-volume production of items like pipes, tubes, and some profiles.
  • Materials:  Silicone, Polysulfone, Polycarbonate & Acrylic

Injection Molding:

Injection molding is a manufacturing technology for the mass production of identical plastic parts with good to tight tolerances.  The materials are first melted and then injected under pressure into a mold, where the liquid plastic cools and solidifies.

  • Process: Molten plastic is injected into a mold cavity under high pressure and cooled to form the part.
  • Advantages: Ideal for complex shapes and precise dimensions. It’s highly automated and efficient for large production runs, offering good repeatability and minimal material waste.
  • Materials:  Peek, Ultem PEI & Torlon® PAI

Compression Molding:

Compression molding is a forming process in which a plastic material is placed directly into a heated metal mold then is softened by the heat and therefore forced to conform to the shape ofthe mold.

  • Process: Plastic material is placed in a heated mold cavity, then compressed to shape the part
  • Advantages: Suitable for large parts and materials that require high-strength properties. It can be more cost effective for smaller production runs compared to injection molding.
  • Materials: PTFE

Pexco specializes in manufacturing extruded, injection, and compression molded plastic parts. We leverage years of expertise to bring your product to market – on time and on budget.

For more information on Pexco and how we can help you with your project, please visit our website at www.pexco.com.

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Let Pexco Solve Your Most Difficult Challenges

July 11, 2024  |  , , ,

Pexco.locations

At Pexco, our strength lies in our solution diversity.  From custom solutions to solving specific engineering challenges, our expertise guarantees outstanding results. From inspiration to application, Pexco has been helping our customers bring ideas to life for nearly half a century.

Pexco embrases the value of working together as One Pexco. This philosphy drives business-level product innovation, location efficiencies, client responsiveness and helps us attract talent. We are able to take advantage of the economies of scale, scope and skill while creating strong accountability and ownership, by pushing decision making down as close to the customer as possible.

Pexco places great value on firm-wide coordination in decision-making, cooperative teamwork and institutional committment. We have one way of doing things and utilize cross-facility teams to address client innovation.

Pexco’s multiple specialty manufacturing facilities across North America help control costs and provide the flexibility needed for fast and efficient product delivery.  And with 13 locations nationwide, we can meet most of your market’s product needs, On-time and on budget:

  • Asheboro, NC   
  • Athol, CT
  • Atlanta, GA – Headquarters
  • Bristol, CT
  • Cincinnati, OH
  • Grand Falls, NB, CA
  • Monterey, MX
  • Philadelphia, PA
  • Plastow, NH
  • Ravena, OH
  • Sparta, NJ
  • Tacoma, WA
  • Wallingford, CT

Pexco specializes in manufacturing extruded, injection, and compression molded plastic parts.  We leverage years of expertise to bring your product to market – on-time and on-budget.

For more information on One Pexco and how we can help you with your project, please contact Rich Reed, Vice President of Sales – Custom, at [email protected] or visit our website at www.pexco.com.

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Expertise is Vital in Custom Plastic Injection Applications

December 14, 2023  |  ,
Ultem PEI Polyetherimide thermoplastic component

Ultem PEI Polyetherimide thermoplastic component

Expertise is incredibly important in custom plastic injection applications. These applications often involve precise specifications and unique requirements, where even slight variations can significantly impact the final product. Close collaboration between the manufacturer and the client is essential to ensure that the design, material selection, tooling, and production processes align perfectly with the desired outcome.

Expertise in this context involves:

  1. Understanding Specific Needs: Engaging with clients to thoroughly comprehend their exact requirements, tolerances, and desired outcomes for the injection-molded parts.
  2. Tailoring Solutions: Customizing the manufacturing process, including mold design, material selection, and production methods, to meet the precise needs of the client.
  3. Material Knowledge:  Knowing material options and access to material suppliers is essential in developing unique custom resin formulations to meet production needs.
  4. Clear Communication: Maintaining open lines of communication throughout the entire process to address any concerns, discuss progress, and make necessary adjustments promptly.
  5. Quality Assurance: Ensuring stringent quality checks and inspections at every stage to guarantee that the final product meets the client’s specifications and standards.
  6. Flexibility and Adaptability: Being able to adapt to changes or refine the process based on client feedback or evolving requirements to deliver the best possible outcome.

Expertise in custom plastic injection applications not only ensures the technical accuracy of the manufactured parts but also builds trust and fosters long-term partnerships between manufacturers and clients.

Performance Plastics is a world-class complex injection molding company.  We work with our customers to leverage the capabilities of ultra and high-performance materials such as PEEK, Torlon®, Ultem®, PFA, FEP, PVDF, and ETFE and can achieve extreme dimension or tight tolerance injection molded parts.

For more information on Performance Plastics’ capabilities, please contact Rich Reed, Vice President of Sales & Marketing at [email protected], or visit our website at 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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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 – 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.

 

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Performance Plastics – Experts in Direct Gating Technology

June 30, 2021  |  , , ,

 

For decades, Performance Plastics has been delivering the highest quality custom plastic injection molding solutions in the industry for our customers. We take a highly specialized and consultative approach, working closely with our customers to develop the solutions needed to solve the most complicated issues.

Direct gating is a molding technique designed to drastically reduce the material waste associated with runner systems. This is critically important when working with sheer sensitive, expensive materials such as fluoropolymers (FEP, PFA, PVDF) and PEEK.

Direct gating is ideally suited for deep draw parts and/or small parts like medical components.  The technique saves resin and typically cuts cycle time by up to 50%.  In addition, it eliminates the need for downstream processing such as surface finishing or grinding.  The part quality achieved by direct gating is in many cases improved over parts manufactured with a cold runner.

We work with design engineers to create better products.  Direct gating is an advanced technique that increases value and provides advantages for new, innovative concepts.  Our hybrid direct gate technology eliminates the runner waste associated with conventional molding, significantly reducing material use and per part cost. Polymers are injected directly into the part mold eliminating the need for runners.

Performance Plastics excels at intricate injection molded components needing some combination of high temperature, low surface adhesion, chemical and organic resistance in a package with complex geometries and/or tight tolerances.

For more information on how Performance Plastics can solve your tight tolerance molding challenges, please contact Rich Reed, VP Sales & Marketing at 513.321.8404 or [email protected].

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