Injection Molding Advances with Biocompatible Fluoropolymers

January 25, 2024  |  , ,

Injection molding has advanced significantly with the use of biocompatible fluoropolymers. Fluoropolymers are a type of synthetic polymer that contains fluorine atoms, providing unique properties such as high thermal stability, chemical resistance, and low friction. When these fluoropolymers are made biocompatible, they become suitable for various medical and healthcare applications.

The use of biocompatible fluoropolymers in injection molding offers several advantages:

  1. Biocompatibility: These materials are designed to be compatible with living tissues and can be safely used in medical devices and implants. This makes them ideal for applications where direct contact with the human body is necessary.
  2. Chemical Resistance: Fluoropolymers are known for their excellent chemical resistance. In medical environments, where exposure to various chemicals is possible, these materials provide a protective barrier against corrosion and degradation.
  3. High Thermal Stability: Fluoropolymers can withstand high temperatures without losing their structural integrity. This property is crucial in medical applications where sterilization processes involve elevated temperatures.
  4. Low Friction: The low coefficient of friction of fluoropolymers makes them suitable for applications where smooth surfaces and minimal friction are essential, such as in medical devices that come into contact with bodily fluids.
  5. Precision Molding: Injection molding allows for the production of complex and precise shapes. This is particularly beneficial in medical device manufacturing where intricate designs are often required for optimal performance.
  6. Cost-Effectiveness: Injection molding is a cost-effective manufacturing process, especially for high-volume production. This makes it an attractive option for producing medical components and devices on a large scale.

Applications of biocompatible fluoropolymers in injection molding include the manufacturing of components for medical devices such as catheters, connectors, seals, and implantable devices.

It’s important to note that the adoption of these materials in medical applications requires compliance with regulatory standards and guidelines to ensure the safety and efficacy of the produced devices. Manufacturers must adhere to strict quality control measures to meet the stringent requirements of the healthcare industry.

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.

For more information on the top of Biocompatible Fluoropolymer Advances, please see our white paper at:

https://performanceplastics.com/blog/biocompatible-fluoropolymers/

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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What is a high-performance plastic?

February 28, 2023  |  , , ,

Plastics can be considered high-performance for a variety of reasons.  The specific application and the performance criteria are the most important.  Here are some characteristics that can contribute to a resin being classified as a high-performance plastic.

  1. Strength and durability: Many plastics are engineered (fiber reinforced) to be extremely strong and durable, with high tensile strength and resistance to wear, tear, and impact. This can make them well-suited for applications where mechanical stress is a concern. Examples include Torlon PAI and PEEK.
  2. Temperature resistance: Certain plastics are highly resistant to chemical corrosion or degradation, which can make them ideal for use in harsh environments or with corrosive substances. Examples include fluoropolymers such as PFA with a melting point of 581 degrees F.
  3. Electrical properties: Some plastics have excellent electrical insulation properties, making them ideal for use in electronics or other electrical applications. Examples include fluoropolymers such as FEP.
  4. Lightweight: Many plastics are lightweight, which can make them ideal for applications where weight is a concern, such as the aerospace, medical, or industrial markets.
  5. Versatility: Plastics can be easily injection molded into a wide variety of complex shapes and sizes, which can make them versatile and useful in a wide range of applications.

Overall, high-performance plastics can be custom designed to meet specific performance criteria and offer a wide range of benefits depending on the application.

For more information on high-performance plastics or other Performance Plastics services, please contact Rich Reed, Vice President of Sales & Marketing at [email protected] or call 440-785-7122.

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Plastic Injection Molding vs 3D Printing (Part 2)

November 16, 2022  |  , , ,

How to choose the best technology for your project.

 

Plastic injection molding and 3D printing are both viable technologies. 3D printing is an additive printing process that creates objects by building up layers of material, while injection molding uses a mold that is filled with molten materials that cool and harden to produce parts.

The use of 3D printing in innovative and experimental scenarios is a viable technology for its ability to create custom plastic part designs quickly.  However, the 3D process limits your material choices, as all materials are not a fit or even available in a form suitable for 3D printing.

3D printing is best used for:

  • Quick turnaround times
  • Low volume, slower production speeds
  • Parts in the design phase with frequent changes – prototyping, lower product quality
  • Smaller part sizes

Once a design has been finalized, plastic injection molding becomes the optimal process.  Most of today’s plastic parts are manufactured using plastic injection molding – it’s best for producing large quantities quickly and reliably in high-volume runs. You have greater material options with plastic injection molding, and you can control material weight, cost, and flexibility with endless combinations of materials.  It helps organizations control the cost and integrity of designs with complexities and tight tolerances.

Plastic Injection molding is best used for:

  • High volume
  • Finalized part design
  • Enhanced strength and durability
  • Complex, precision, detailed parts

At Performance Plastics we have optimized many projects that were once manufactured using 3D printing, only to discover that injection molding was the more efficient technology.  As experts in FEP, PFA, PAI (Torlon), PEEK, and Ultem resins we frequently work with mission-critical, time-sensitive applications.  3D printing is an essential component of the design process, but If you have a project that requires high volume (5,000+ parts per year), high-temperature resins, and tight tolerances with complex geometries, plastic injection molding is your solution.

Performance Plastics’ team of experienced engineers possesses the expertise to design and manufacture technically challenging projects and offer complex solutions within harsh application industries.

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

 

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Teflon®- Why Machine when you can Injection Mold

September 13, 2022  |  , , , , ,

Performance Plastics specializes in the precision injection molding of technically complicated parts in advanced materials, eliminating the need to machine.

High performance plastic materials offer ideal properties when it comes to durability. Resins like polytetrafluoroethylene (PTFE/Teflon®) are known for their dielectric strength, low dissipation, chemical resistance, outstanding performance at elevated temperatures, and levels of coefficient friction. However, these unique properties can make molding some fluoropolymers quite difficult. Performance Plastics has found a way to offer the benefits of these materials by injection molding alternate fluoropolymers such as FEP and PFA.

At Performance Plastics, we are experts at precision injection molding. We have developed proprietary tool design software, processes and equipment enabling us to injection mold components having complex geometries made from challenging high-performance thermoplastic materials (PFA/FEP/PEEK®/PTFE/Teflon®) and highly loaded compounds. We utilize a unique combination of extensive material knowledge, mold flow analysis, a design system and process expertise to eliminate or minimize the need for secondary operations.

Switching from machining parts to injection molding parts can be very beneficial. Not only does injection molding help lower costs, but it also allows for highly efficient production, complexity in part design, and enhanced part strength. Injection molding produces uniformity, the ability to make millions of virtually identical parts.

Injection molding isn’t for every project, but it can be cost beneficial for applications producing more than 10,000 pieces of the same part year over year. At Performance Plastics, we serve a variety of industries, from medical & life science, aerospace & defense to diversified industrial.

To learn about how precision injection molding can replace machined parts, contact Rich Reed, our Vice President of Sales and Marketing, at (513) 321-8404 or [email protected].

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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].

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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] 

 

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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

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Ultem® Use in Aerospace Applications

June 1, 2022  |  , , ,

Ultem PEI Polyetherimide thermoplastic component

Ultem Polyetherimide is a material widely used in the aerospace industry.  It is often applied to aircraft components for weight reduction in place of metal parts.  Additionally, since it has a high thermal resistance rating, polymer components have the benefit of evading radar detection in military aircraft.

ULTEM is among the few resins approved for use in the aerospace sector. 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. Its flame-resistance ensures that it meets FAA regulations for flammability.

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.  It is also flame resistant with extremely low smoke generation. ULTEM is FDA and NSF approved for both food and medical contact resistance act and therefore is an excellent choice for aircraft galley equipment such as ovens, microwaves and hot or cold beverage dispensing systems.

Ultem is now widely used in:

  • Personal Service Units
  • Oxygen Panels
  • Ventilation Systems
  • Connectors
  • Cable Ducts
  • Latches
  • Hinges
  • Food Tray Containers
  • Door Handles
  • Interior Cladding Parts

Ultem offers exceptional balance of flame retardancy, low smoke emission and low smoke toxicity making it an excellent candidate for aerospace and aircraft 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]

 

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Ultem® Use in Medical Applications

April 20, 2022  |  , , , ,

Ultem Polyetherimide is a material widely used in the medical industry.  It is a highly sought-after thermoplastic for its weight saving characteristics and for its use in reusable autoclave sterilization components.  Thermoplastic resins become more pliable at warmer temperatures which combined with strength characteristics, thinner walls and larger inner diameters make it a great option for medical tubing such as medical devices.

Thermoplastic polyurethanes dominate the catheter market and are used in some diagnostic and guiding designs. Extruded thermoplastic or thermoset materials are often used in cardiology or interventional radiology.   Polyamides and polyamide block copolymers dominate the percutaneous transluminal coronary angioplasty catheter market. They are the polymer of choice for balloon catheters and for stent delivery catheters.

 

Thermoplastic urethanes and polyether block amides are perhaps the most used thermoplastic elastomers in applications such as catheter tubing, balloons, wound dressings, surgical drapes, storage bags, strain reliefs and numerous other medical device applications.

Ultem is now widely used in:

  • Structural Medical Components
  • In Vitro Diagnostics
  • Medical Respiratory Devices
  • Infusion Pumps
  • Radiation Therapy Systems

Ultem has exceptional dimensional stability and machinability which makes it suitable for intricate medical devices. It can be molded with different materials like glass fibers, minerals, carbon fibers, etc. to enhance the mechanical strength of the products.

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]

 

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Performance Plastics is pleased to announce the addition of new equipment featuring AI

February 16, 2022  |  , ,

Performance Plastics – is pleased to announce the addition of a new piece of high-performance plastic injection molding equipment – A Milacron Robo Shot Alpha SIB Series.

Milacron Fanuc Robo Shot S150iB – High Precision Electric Injection Molding is the next generation of AI in injection molding machines, with higher precision for more reliable molding capabilities.  The Robo Shot’s proven performance makes it the perfect solution for molding environments that demand precise process control, high speed injection and consistent repeatability.

“The investment in this new piece of equipment expands our capacity to produce high volume, technically challenging parts for our customers” stated Rich Reed, Vice President of Sales & Marketing.  “We aspire to become an invaluable customer resource in solving our customers engineering challenges”.

With no oil supply, filtration or disposal, the Robo Shot is an energy saving “green” machine that will help reduce operational and energy costs.  It is engineered to reduce energy consumption by 50 to 80% with repeatable and precise cycles that are 5 to 50% faster compared with traditional hydraulic machines.

Performance Plastics specializes in high-performance injection molding thermoplastics 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.

 

https://www.prweb.com/releases/2022/2/prweb18503704.htm

 

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