Nutplates fail for a variety of reasons
Following aircraft specific T.O. – takes from 24 to 72 hours to effect a repair
Removal-and-Replacement-of-Failed-Bonded-Nutplates-Presentation
Computed Tomography Measures Tighter Tolerances
Plastic injection molding continues to become more and more sophisticated with part tolerances becoming tighter and tighter. Initially, tight tolerance was defined as +/-.002 inches (0.0508 mm) and a very tight tolerance is +/-.001 inches (0.0254 mm) But today there are many factors that impact tight tolerance including part complexity and size, resin selection, tooling, and process conditions. So, getting the mold, part design, material selection and process correct is crucial when working with a product that requires tight tolerances.
Tight tolerances are essential when manufacturing complex parts, especially in the aerospace & defense, medical & life sciences, and diversified industrial sectors. A few thousandths of an inch can be the difference between a component that fits and one that does not – if tight tolerances are not achieved properly the resulting products may underperform. So, it is critical that clients understand tight tolerances and their underlying objectives. Performance Plastics has parts in production that are +/-.0004 inches (0.01016 mm). Parts are measured in their Metrology lab with a CT Scanner. Engineers use Zeiss metrology equipment to analyze every aspect of parts and the problem at hand, not just the data on the part dimensions and the dimensional tolerances.
Benefits of Tight Tolerances
There are many benefits to manufacturing parts with tight tolerances. It ensures that parts work together smoothly and fit as intended in their final form; parts mesh well and deliver enhanced functionality. They produce lower failure rates and result in higher client satisfaction. Tight tolerances can also result in fewer post-molding processing requirements. Additionally, tight tolerances allow for parts to be transitioned from metal to plastic, reducing overall weight and cost of the final product. This can be very advantageous in some industries, such as aerospace and defense.
Design for Tight Tolerances
Not every plastic injection molding project requires tight tolerances, and some organizations insist on tight tolerances for non-critical features. Tight tolerance should only be required in instances where they are critical. Many products require standard tolerancing because the consequences of failure are low. As a general rule, designers should keep tolerances as large as possible while maintaining the desired functionality of the part.
Materials for Tight Tolerances
Additionally, material selection is a critical element in achieving tight tolerances. Certain resins perform better under certain circumstances. An experienced design engineer can guide a client in choosing the most affordable material that will deliver the best result. So, it’s critical to bring in an experienced team early in the design process.
By engaging a production team during the design phase, part functionality, material selection and design can be discussed upfront, and the team can jointly develop a manufacturing process and correct materials that will produce high-precision components. It is crucial for organizations to partner with an experienced injection molder, who has expertise; the design and manufacturing teams should be integrated to allow manufacturability issues to be identified and addressed during the design process – thus saving significant time and unnecessary cost.
Establishing the right process and correct materials for each product and developing repeatability are key to manufacturing tight tolerance parts. While every application is different, there are some process and material conditions that impact tolerances. For example, quick cavity filling and uniform cooling at the desired temperature are conditions that are crucial to achieving repeatability, and thus, parts with tight tolerances.
Plastic injection molding continues to become more and more sophisticated with part tolerances becoming tighter and tighter. Initially, tight tolerance was defined as +/-.002 inches and a very tight tolerance is +/-.001 inches. But today there are many factors that impact tight tolerance including part complexity and size, resin selection, tooling, and process conditions. So, getting the mold, part design, material selection and process correct is crucial when working with a product that requires tight tolerances.
Tight tolerances are essential when manufacturing complex parts, especially in the aerospace & defense, medical & life sciences, and diversified industrial sectors. A few thousandths of an inch can be the difference between a component that fits and one that does not – if tight tolerances are not achieved properly the resulting products may underperform. So, it is critical that clients understand tight tolerances and their underlying objectives. Performance Plastics has parts in production that are +/-.0004 inches. Parts are measured in their Metrology lab with a CT Scanner.
Benefits of Tight Tolerances
There are many benefits to manufacturing parts with tight tolerances. It ensures that parts work together smoothly and fit as intended in their final form; parts mesh well and deliver enhanced functionality. They produce lower failure rates and result in higher client satisfaction. Tight tolerances can also result in fewer post-molding processing requirements. Additionally, tight tolerances allow for parts to be transitioned from metal to plastic, reducing overall weight and cost of the final product. This can be very advantageous in some industries, such as aerospace and defense.
Design for Tight Tolerances
Not every plastic injection molding project requires tight tolerances, and some organizations insist on tight tolerances for non-critical features. Tight tolerance should only be required in instances where they are critical. Many products require standard tolerancing because the consequences of failure are low. As a general rule, designers should keep tolerances as large as possible while maintaining the desired functionality of the part.
Materials for Tight Tolerances
Additionally, material selection is a critical element in achieving tight tolerances. Certain resins perform better under certain circumstances. An experienced design engineer can guide a client in choosing the most affordable material that will deliver the best result. So, it’s critical to bring in an experienced team early in the design process.
By engaging a production team during the design phase, part functionality, material selection and design can be discussed upfront, and the team can jointly develop a manufacturing process and correct materials that will produce high-precision components. It is crucial for organizations to partner with an experienced injection molder, who has expertise; the design and manufacturing teams should be integrated to allow manufacturability issues to be identified and addressed during the design process – thus saving significant time and unnecessary cost.
Establishing the right process and correct materials for each product and developing repeatability are key to manufacturing tight tolerance parts. While every application is different, there are some process and material conditions that impact tolerances. For example, quick cavity filling and uniform cooling at the desired temperature are conditions that are crucial to achieving repeatability, and thus, parts with tight tolerances.
Performance Plastics is highly skilled at designing and molding using high performance materials such as PEI-Ultem®, PAI-Torlon®, Ryton® PPS Plastic, PEEK, and Fluoropolymers such as FEP, PFA, and PVDF. We work with our customers to solve technically challenging problems. We can propose materials to implement part functionality in the design stage of development. We offer manufacturing solutions such as a clean room, the ability to offer direct gating of fluoropolymers, high volume production, visual inspection, and automated facilities.
For more information and solutions, please contact Rich Reed, Vice President of Sales & Marketing at 513-321-8404 or email [email protected]
When trying to choose the correct polymer for your application, understanding the materials can help you make your decision. For parts that require superior strength and durability, Ultem® is often a great choice.
Ultem® is a semi-transparent high strength plastic material that can operate in high service temperature environments. It is the ideal choice for demanding, high heat applications and can withstand continuous operating temperatures of 340 degrees F while maintaining strength and rigidity.
Ultem® is a member of the PEI (polyetherimide) family of thermoplastic resins. It provides a unique balance of mechanical properties and processability that gives engineers superior flexibility and freedom in design. Ultem is available in a variety of grades that provide enhanced chemical, heat, and elasticity benefits. It also features high tensile strength, stiffness, strength to weight ratio and dimensional stability.
Ultem® is the high-performance polyetherimide material of choice for many aerospace, aircraft, medical and pharmaceutical applications, including medical components. It offers exceptional mechanical properties and exhibits natural flame resistance and extremely low smoke generation.
Performance Plastics is highly skilled at designing and molding using high performance materials such as Ultem®, Torlon®, PEEK, POM, and PPS. We work with our customers to solve technically challenging problems. We can propose materials to implement part functionality in the design stage of development. We offer manufacturing solutions such as a clean room, the ability to offer direct gating of fluoropolymers, high volume production, visual inspection and automated facilities.
For more information and solutions, please contact Rich Reed, Vice President of Sales & Marketing at 513-321-8404 or email [email protected]
Insert Molding and Overmolding are very similar processes, but there are distinct differences between the two techniques. Insert molding is a slightly faster one step process because two plastic materials are molded at the same time, while overmolding is a two-step process where two separately molded parts are combined to enhance the parts performance.
Insert molding is a process which adds metal parts to injection molded parts during molding rather than after the parts have cured. This reduces the time for post-molding manufacturing/assembly operations. Inserts are placed into the mold cores or cast into the molds themselves. After the mold closes, plastic pellets are plasticized in the injector barrel and shot into the mold, the plastic material flowing around the captured inserts. Once the plastic hardens, the pieces are ejected from the mold, with the inserts now enclosed in the parts. Insert molding is a single-shot process
Insert molding is a common manufacturing method for producing connectors, electronic sockets, in addition to in making parts that are assembled with threaded fasteners. Insert molding is used to provide protective surfaces on many aerospace, defense, and medical/surgical devices.
Insert molding is also the term used to describe the overmolding technique of adding a layer of plastic material onto an existing metal or plastic part. Here, also, the metal or plastic part is placed into a single-shot injection mold and the over-mold material is injected around it.
Overmolding is an advanced plastic injection technique that creates parts from two or more materials. Typically referred to as “in-mold assembly”, overmolding can be facilitated by either using the insert molding technique, or a multi shot molding technique.
Plastic overmolding, sometimes called multi-shot molding, adds additional material such as thermoplastic elastomer (TPE). Multi-shot molding is usually performed by way of multi-barrel injection molding machines, the process adding additional material shortly after the base is formed to create strong bonds between materials. Plastic overmolding serves to eliminate steps in the manufacturing process while creating enhanced injection molded products.
Depending on the materials selected for the base and the over-mold, materials may be bonded chemically or mechanically. Inserts made of brass are common, but steel and stainless steel are also used. Many of the inserts are knurled on the outside or have special shapes that hold the insert in place. Among the many materials that are suited to overmolding, polycarbonate, ABS, Ultem, and nylon. Over-mold materials include PEEK (Polyetheretherketone), FEP & PFA Fluoropolymers, (Neoflon, Polyflon) and PEI (Polyetherimide) Ultem.
Multi-shot overmolding has many applications such as medical instruments where it can provide enhanced grip, sterilization, moisture protection, and so on. Automobile and Aerospace manufacturers use overmolding to reduce the need for additional assembly steps that would require using adhesives.
Insert Molding and Overmolding are very similar but have distinct differences. Insert molding is a one step process, while overmolding is a two-step process where two separately molded parts are combined to enhance the parts performance.
At Performance Plastics, we understand that working with a qualified molding company is crucial to your company’s success. It is vital to find a team to support your company’s mission and commitment to delivering quality products on time. We have found over time, that there are three essential components that should weigh in your decision-making process when choosing a molder for your next application: Education, Trust and Quality.
Education
Is your molding partner educated about your company and your products? Do they understand your needs and goals? Do they understand advanced materials and their properties? Understanding resins and best molding practices including raw materials, drying time, heat history and molding temperatures will affect the outcome and quality of your application.
Trust
Trust is important in any business relationship – especially one that reflects on your business. Do you trust your molding partner to properly do the job? Open and continuous communication with key management of your molding partner is crucial to the success of any application. Your team should keep you informed of market conditions pertaining to raw materials, new techniques, and opportunities for improvement?
Quality and Quantity
Quality and Quantity, both are important to your business. Your customers rely on you for quality, dependable parts, but you must rely on your team for an on-time and dependable process. Dependable processes, such as quality procedures, run rates and material quality control produce quality parts.
Performance Plastics, located in Cincinnati, OH has over 30 years’ experience molding tight tolerance advanced plastics such as Fluoropolymers (FEP/PFA Torlon, Peek & Ultem) for many industries. We have developed proprietary processes enabling injection molding of parts that are thin walled, with tight dimensional tolerances, and complex geometries.
Education, Trust and Quality. Think about these questions when choosing your molding partner. Remember – education, trust, communication, and quality of work are vital to a long-lasting business relationship. Ask the questions and get some answers. This will assist you in finding and maintaining a dependable partnership.
For more information and solutions, please contact Rich Reed, Vice President of Sales & Marketing at 513-321-8404 or email [email protected].
Performance Plastics LLC is pleased to announce the renewal of our ISO 9001:2015 certification, valid from March 2021 through March 2024. The ISO 9001:2015 Standard for Quality Management System is applicable to all our processes including development, sales, production, service and after sales.
At Performance Plastics, our Quality Policy revolves around ensuring that requirements are met while continually improving our Quality Management System. Creating customer satisfaction is our number one goal. The ISO 9001 standard is based on several quality management principals including a strong customer focus, the motivation and implementation of top management, the process approach and continual improvement. ISO 9001 ensures that customers get consistent, good-quality products and services, which in turn ensures your satisfaction. Each of our custom projects receives the same attention to quality.
Performance Plastics, located in Cincinnati, OH has over 30 years’ experience in molding tight tolerance advanced plastics such as Fluoropolymers (FEP/PFA Torlon, Peek & Ultem) for many industries. We have developed proprietary processes enabling injection molding of parts that are thin walled, with tight dimensional tolerances, and complex geometries. For more information and solutions, please contact Rich Reed, Vice President of Sales & Marketing at 513-321-8404 or email [email protected].
As you’re desig
ning 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 damaging your samples? At Performance Plastics, we offer the services of industrial computed tomography (CT) scan. This provides us the ability to measure all aspects of your part, without having to damage it.
Industrial CT scanning in the design process 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. In addition, 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:
Performance Plastics, located in Cincinnati, OH has over 30 years’ experience in molding tight tolerance advanced plastics such as Fluoropolymers (FEP/PFA Torlon, Peek & Ultem) for many industries. We have developed proprietary processes enabling injection molding of parts that are thin walled, with tight dimensional tolerances, and complex geometries. For more information and solutions, please contact Rich Reed, Vice President of Sales & Marketing at 513-321-8404 or email [email protected].
Every project has its own needs and goals. Complex geometries involving fine details or sharp corners often cannot be achieved by traditional plastic molding. Advanced plastic injection molding processes allow designers to combine numerous complex features into a single component, reducing the need for secondary machining or surface finishing operations.
Plastic Injection molding allows design freedom not easily matched by other traditional processes. Performance Plastics’ augments the latest software tools including solid modeling, mold flow analysis and finite element analysis with an internally developed iterative tool design approach to deliver complex geometries and densities superior to most other operations.
Our tooling modification process results in best in class part tolerances, particularly useful in molding mission critical parts where dimensional attributes need to be extremely precise. We use this approach to produce net shape molded parts of exceptional quality, eliminating or significantly reducing secondary matching operations resulting in material and process cost savings.
Performance Plastics, located in Cincinnati, OH has over 30 years’ experience in molding tight tolerance advanced plastics such as Fluoropolymers (FEP/PFA Torlon, Ryton plastic, Peek & Ultem) for many industries. We have developed proprietary processes enabling injection molding of parts that are thin walled, with tight dimensional tolerances, and complex geometries.
For more information and solutions, please contact Rich Reed, Vice President of Sales & Marketing at 513-321-8404 or email [email protected].
At Performance Plastics, our primary job is to facilitate designs that create better products. Our direct gating technology does just that by increasing the value of existing products and providing 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.
Direct gating is suited for deep draw parts such as pipettes and syringe barrels or for small parts like medical infusion components. This saves both resin and typically cuts cycle time by up to 50%. In addition, it eliminates the need for downstream processing of the cold runner, which in medical applications can not typically be used as regrind. The part quality achieved by direct gating is in many cases improved over parts manufactured with a cold runner.
Part quality is always critical in the medical industry due to safety concerns. With medical parts, sharp edges or pronounced gate vestiges can potentially tear latex gloves or even skin. In the medical industry, even seemingly small improvements in quality can make a significant difference in everyday applications and safety.
Performance Plastics excels at helping customers create intricate injection molded components that can benefit from a combination of high temperature, low surface adhesion, chemical and organic resistance in a package with complex geometries and/or tight tolerances.
Performance Plastics has developed a number of industry leading technologies enabling us to injection mold intricate, thin walled components out of some of the most sheer sensitive materials such as fluoropolymers. This is critically important when working with sheer sensitive, expensive materials such as fluoropolymers (FEP, PFA, PVDF) and PEEK.
Performance Plastics Ltd offers high-performance injection molding thermoplastic expertise featuring tight tolerances and thin walled part geometries. The industries we serve include aerospace/defense, medical and industrial applications. For more information, please visit our website at www.performanceplastics.com or [email protected].
