Get to Know Performance Plastics

September 1, 2022  |  , ,

You know Performance Plastics for our EnduroSharp® Non-marring Aircraft Maintenance Tool, but did you know that Performance Plastic is also an expert in tight tolerance custom injection molding?

For four 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.

We have the experience to take a project from concept to production in-house. Every step of the process, from design and engineering, to tooling, protype, and full production, is done under the supervision of our experienced team. We produce complex, tight tolerance custom molded products of all types for the aerospace, medical and diversified industrial sectors.

We are technical specialists in collaborating and executing advanced, custom solutions for our customers. Injection-molded product fabrication is a complex process, especially when dealing with parts that are the size of a pin.  Our process is comprehensive and efficient to ensure that custom solutions can be delivered quickly and cost-effectively. High performance materials include PFA, FEP, PEEK, ULTEM, and Torlon.

With the ability to injection mold shot sizes as small as .015 grams with a wall thickness as thin as .008 of inch, Performance Plastics is anything but typical.  We are one of the leaders in tight tolerance, highly detailed medical parts.

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].

 

 

/by

Types of Plastics used in the Semiconductor Industry

August 23, 2022  |  , , , ,

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

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

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

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

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

 

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

 

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

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

/by

PEEK® Use in Medical Applications

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

High Precision, PEEK, Thermoplastic Medical Spinal Implant Component

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

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

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

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

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

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

/by

The real cost of making an injection mold

August 9, 2022  |  , , , ,

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

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

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

  • Choice of Resin

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

  • Complexity

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

  • Size

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

  • Mold Material

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

  • Cavities

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

  • Mold Base

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

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

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

/by

Injection Molded PFA for Semicon Meets F-57 Requirements

August 2, 2022  |  , , ,

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

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

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

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

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

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

/by

PEEK, PAEK and PEI are Great Alternatives During Material Shortages

July 19, 2022  |  , , , ,

Navigating supply chain issues in this economic environment where there are rampant material shortages is an ongoing challenge. But many commonly used engineered resins may serve well as replacements for your application. Performance Plastics are experts in material selection and can assist your organization in choosing the best material based on the functionality of your part.

PEEK (Polyether Ether Ketone), PAEK (Polyaryletherketongs) and PEI (Polyetherimide) are high performing engineering thermoplastics that offer a unique combination of thermal stability, chemical resistance, and excellent mechanical properties.

PEEK is extremely tough and has very high impact strength.  Due to the crystalline nature of the material, a high degree of mechanical properties is retained close to their melting temperature.  The also have a low creep and good wear properties.  It is also known for excellent chemical resistant during hydrolysis. PEEK is actively used in metal to plastic replacement applications.

PAEK is a high thermal stability material that offers high strength and high resistance to oxidation. It offers better solvent resistance and is more amorphous based on its semi-crystalline structure.  This makes it an excellent choice for medical components, sea equipment and valve components.

PEI is a high-performance engineering plastic that offers outstanding thermal, mechanical and chemical properties.  It is often the best choice where high mechanical strength is needed in conjunction with high temperature, corrosion and wear resistance. This makes PEI an excellent alternative for applications requiring tight tolerances and low warp such as medical devices, scientific equipment parts and semiconductor equipment components.

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

/by

It’s Not Tight Tolerance Unless You Can Measure It – Industrial CT Scanning

July 12, 2022  |  , , ,

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

Industrial CT scanning gives you access to the inner workings of a part without having to destroy the original. The scanner rotates the part 360 degrees and uses X-rays to create a precise 3D model. This allows for a thorough analysis of object dimensions, porosity, wall thickness, assembly defects, comprehensive comparisons, and reverse engineering.

The CT scan can then be compared to the CAD model and to other parts. Plus, it can easily analyze surface variations and provide cross sections to reveal hidden features.

Performance Plastics now offer a variety of CT scan-related services:

  • Part-to-CAD comparisons create a precise overlay of the scanned part to the original 3D part model database
  • Part-to-part comparisons provide an overlay of two scanned parts to reveal dimensional deviation
  • Void and inclusion analysis provides material and defect analysis showing void or inclusion size and locations
  • Wall thickness analysis measures slight changes in the wall stock of complex parts without destructive testing
  • Dimensional analysis provides full article inspections and reporting
  • Reverse engineering capabilities that generate a 3D CAD file

Industrial CT scanning can be necessary during five different manufacturing stages. When you’re in pre-production, it can help with the project design and analysis. During production, you can use CT scanning to evaluate consistency. At the failure investigation stage, it will find defects. The CT scanner can run repeatability tests when you’re doing inspections. And if you need design adjustments or are doing further R&D, it can help with reverse engineering.

As for what Performance Plastics can handle when CT scanning:

  • Maximum part size is 300mm diameter x 350 mm tall
  • Scan time is typically less than one hour
  • Accuracy (using Calypso) of 9+L/50 microns
  • X-ray-based measurement system is non-contact
  • Parts do not require potting

At Performance Plastics, we are experts in injection molding, specializing in high performance plastics for medical device components. 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]  

 

/by

Benefits of Reshoring for Medical Device Manufacturers

June 28, 2022  |  , , , ,

Medical devices must be dependable and safe, and moving operations back to the United States allow companies to have better control over the entire operation – procurement, engineering, production, and distribution.  The result is a higher standard of quality in products.  Medical device companies and other advanced industries need to have extensive and precise control over the entire supply chain of their products.

As an American small business, Performance Plastics is pleased to see the trend of manufacturing operations moving back to the United States.  A range of economic and strategic factors due to the recent epidemic have tipped the scales exponentially since 2020.

While there are many benefits of reshoring, some of the most important reasons include:

  • Greater Control of Supply Chain

Getting all your moving pieces to work seamlessly can be a near impossible task, especially across language and time zone barriers.  One of the primary advantages of reshoring is that it allows you to tighten your supply chain.

  • Reduced Lead Times

The greater the distance between where your device is manufactured and where you are located, the longer you can expect your lead time to be.  However, distance is not the only factor.  When moving from one country to another, inspection and transportation times between countries can add up to 50% to your lead time.

  • Fewer Import Tariffs

Import tariffs vary from administration to administration, but they will always be in place.  The recent increase in tariffs have caused the cost advantages of manufacturing offshore to shrink.

  • Reduced Energy Costs

Recent changes to international gas and power prices have drastically increased the prices of manufacturing and transportation from other countries.  Impact on the environment and achieving higher sustainability are very important to consumers.

  • Potential to Improve Brand Perception

Although we live in an international community, the origin of a product still has an impact on the perception of quality.  Some lower cost manufacturing countries even have a perception of being “dangerous”.

Medical devices necessitate the highest quality standards possible, which can’t always be regulated in an offshore manufacturing environment.  The vast global, economic, legal and social changes are all very dynamic and unpredictable in nature – making relocating operations a more sustainable, stable and efficient choice.

At Performance Plastics, we are experts in injection molding, specializing in high performance plastics for medical device components. 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] 

 

/by

Ultem® Use in Industrial Applications

June 21, 2022  |  , , ,

Ultem Polyetherimide is a material widely used in industrial applications.  It is an amorphous material with exceptional strength, flame resistance and generates very low levels of smoke. It is often used in the production of circuit boards, sterilization equipment, battery components and oil and gas equipment,

ULTEM is commonly used in industrial applications needing a durable, high-performance, cost-effective alternative to metal: strong enough to replace steel in some applications and light enough to replace aluminum in others.   It outperforms comparable thermoplastics when it comes to resisting creep and does not degrade under repeated mechanical stress. It also holds up well when brought into contact with various fuels, coolants, and lubricants

ULTEM has one of the highest dielectric strengths of any thermoplastic material. It works very efficiently as an electrical insulator. ULTEM also has one of the lowest rates of thermal conductivity, allowing parts machined from ULTEM to act as thermal insulators. ULTEM offers excellent long-term heat resistance with its mechanical and physical properties remaining stable at elevated temperatures.  Unlike most other amorphous plastics, ULTEM resins retain strength and resist strength cracking when exposed to environmental stresses.

Ultem is now widely used in:

  • Automotive
  • Semiconductor
  • Telecom Components
  • Molded Interconnect Devices
  • HVAC/Fluid Handling Devices
  • Oil & Gas Applications

At Performance Plastics, we are experts in injection molding, specializing in high performance plastics. Ultem® is an amorphous material, which can cause complications during the injection molding process. A specific set of conditions, equipment, and processing procedures must be followed to effectively injection mold Ultem®. 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.

Ultem® is one of the many high-performance polymers in which Performance Plastics specializes.  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].

/by

High Performance Polymers – A Great Alternative for Medical Devices

June 9, 2022  |  , , ,

Diabetes care has seen several innovations through the years. One of the most important developments is the insulin pump, which for many patients provides an option to the traditional needle and syringe approach to insulin injections. Insulin pumps are small, computerized devices that are about the size of a small cell phone.  Insulin pumps deliver doses of insulin, the hormone that regulates blood sugar, on a pre-programmed schedule.

High performance polymers have enabled medical device manufacturers to go beyond the functionality of ordinary plastic materials to develop innovative devices for treating diabetic patients.  Resins such as FEP and PFA fluoropolymers are chemically resistant resin with outstanding properties and are currently used in numerous healthcare applications. Physical properties of resins such as high tensile strength, dimensional stability, excellent friction and wear characteristics and the ability to replicate fine features are important advantages as parts become smaller and thinner.

In developing new and advanced insulin delivery devices, resins offer unique advantages and have expanded the possibilities for innovative design and manufacturing. Medical grade fluoropolymers, such as FEP and PFA allow for the miniaturization of device components without the constraints of glass or ordinary plastic materials. With these capabilities, designers can now expand design performance and possibilities. Fine detail replication resulting from the material’s high flow and excellent dimensional stability properties position resins as an excellent material for lightweight and compact precision delivery devices.

Device components such as insulin storage require the use of a proven polymer materials. In addition to compatibility with insulin, purity and very low levels of leaching, resins provide excellent moisture barriers and extremely low water absorption, both necessary properties for optimal long-term drug container storage. These resins are also FDA approved and are compatible with all conventional sterilization methods from gamma to steam.

In future insulin delivery systems, the use of FEP and PFA resin components for various parts of the device will continue to rise. With the advantages engineering polymers offer for design innovation and performance, resins will continue to be the material of choice for delivery applications.

At Performance Plastics, we are experts in injection molding, specializing in high performance plastics. 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].

 

 

PFA plastic (Fluoropolymer) Thermoplastic Components

/by