PEEK For Industrial Applications

October 18, 2022  |  , ,

gears made out of Ryton plastic

PEEK is a high-performance engineering plastic with outstanding resistance to harsh chemicals, excellent mechanical strength, and dimension stability. PEEK (Polyetheretherketone) is an organic thermoplastic polymer, comprised of a semi-crystalline structure which gives it a strong chemical structure.

PEEK is an excellent choice for industrial applications because of its ability to resist harsh conditions:

Resistant to a Wide Range of Chemicals: 

PEEK performs in the toughest chemical environments, capable of resisting more than 140 types of acids, bases, oils, liquids, salts, and elements.

 Immense Temperature Resistance: 

PEEK has an extremely high melting point at 662 °F. It can be used in applications with temperatures up to 482 °F. 

 Extended Resistance to Hydrolysis Process: 

Hydrolysis refers to the chemical process where water is added to a substance. PEEK has the ability to withstand exposure to steam and water for long periods of time without degrading.

 Great Durability: 

PEEK is tough, stiff, and extremely strong.  It has the capability to withstand friction and can perform for long periods of time without suffering from wear and tear.

PEEK is an optimal choice for industrial applications. Most industries see PEEK as the preferred material for parts that are used in extremely harsh application industries. These include oil and gas, mining, heavy equipment, and renewable energy.

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 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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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].

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Performance Plastics Key Capability –  Net Shape Thermoplastic Peek Seals

May 11, 2022  |  , , , , ,

 
Mating parts providing a fluid or gas seal are critical components in most mechanical systems. We commonly think of them in valves and connector assemblies, but they are also found in pressure vessels, compressors, pumps, motors, engines, transmissions, and almost all mechanical power trains. Seals, especially those that mate to moving parts, have a demanding set of quality requirements. Each application has its own specific needs, but all seals are characterized by tight dimensional tolerances and excellent surface finish.

Our customer wanted to improve the usable life and leakage profile of a valve without absorbing any increase in component cost.  The sealing surface specifications were tightened to 0.0005 inches (12.7 µ) which was key to accomplishing the performance improvements.

The previous supplier of this component was unable to meet the more stringent sealing surface dimensional tolerances “out of the mold” necessitating a finish machining operation to bring the part into tolerance.  However, machining the sealing surface removed the resin-rich surface of the part creating micro-cracks in the surface and exposing reinforcing fibers. Both of these unavoidable consequences of machining negatively impacted component performance, useful life and cost.

Solution

Performance Plastics knew eliminating the machining operation would improve strength, reduce trapped impurities, and lower manufacturing cost.  Our engineering team focused on producing a “true net shape” part directly out of the mold.   Key to accomplishing the customers goals involved leveraging our proprietary, iterative tool design process.  It required making a 3D CT scan of preliminary molded parts measuring, in this case, approximately 1 million critical part dimensions.  This analysis identified minute distortions.  Utilizing internally developed proprietary software, PPL integrated the CT scan data with CAD/CAM software to make exacting mold modifications eliminating the out of tolerance conditions.  This process contributed to producing a best in class “out-of-mold” conforming part.

The manufacturing process also had to be optimized to produce the desired performance results.  Although the material posed molding challenges, PPL decided to direct gate the part at the top to ensure symmetry of material flow throughout the cavity, critical in achieving roundness to the sealing surface.

The results of development program surprised everyone. Performance Plastics was able to achieve  “out of mold” net shape parts with a seal surface capable of meeting sealing ranges of 100 psi to 3,000 psi, with no porosity and consistently meeting dimensional tolerances of 0.0003 inches, or 7.62 µ. Eliminating the need for subsequent finish machining dropped the leakage rate for the valve by 50%, from 1.0 scfm to 0.5 scfm.

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]

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Torlon (PAI) Polyamide-imide for Complex Industrial Applications

January 19, 2022  |  , , ,
Torlon Performance Plastic component

Torlon Performance Plastic component

Highly engineered plastic formulations can achieve higher strength to weight ratios than traditional lightweight alloys such as aluminum and titanium.

Torlon® polyamide-imide is the highest performance plastic that is still melt processible, making it ideal for complex geometries.  Torlon® possesses a 500°F heat distortion temperature and a 500°F continuous service temperature allowing for usage at elevated temperatures while maintaining superior strength. Its ability to resist distortion under high temperature makes it perfect for industrial applications.

Long term reliability under strenuous conditions makes Torlon® ideal for load bearing, sealing and isolation applications.  The material provides significant advantages over metals when corrosion is an issue.   Torlon® has demonstrated superior resistance to degradation when exposed to elements such as PH levels and radiation.

At Performance Plastics, we are experts in injection molding, specializing in high performance plastics.  Torlon® is a reactive polymer, 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 Torlon®. 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.

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. Our expertise in process control allows us to effectively injection mold Torlon® in parts with extremely complex industrial applications. This gives us the ability to provide an injection molded part made from the highest strength and stiffness of any commercial thermoplastic.

Torlon® is one of the many high performance polymers Performance Plastics specializes.  For more information on Performance Plastic’s capabilities, please contact Rich Reed, our Vice President of Sales and Marketing at 513.321.8404 or email at [email protected]

 

 

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Injection Molded PFA in the Lithium Ion Battery

December 17, 2021  |  , , , ,

The Lithium Ion Battery industry has begun using more and more plastic parts in their manufacturing processes. Most batteries intended for light vehicle usage now have 50% more plastic materials than they did even 10 years ago.  Some batteries have entirely plastic formulations ranging from the electrolyte (polymeric electrolytes) to the casing.  This is due to the very low weight of plastics as compared to metals. Plastic incorporation in batteries increases the electrolyte efficiency if used in polymeric electrolytes.

Commercially available lithium-ion batteries also use plastics. Plastic components incorporated in batteries include separators, gaskets, and casing components. Plastics have good shock absorbing characteristics and prevent damage to the basic cell unit from minor accidental shocks. Also, plastics such as Teflon® PFA, Ultem® PEI, and PPSU have high temperature resistance, corrosion resistance, and are electrical insulators so they are excellent at preventing short-circuit and “rapid disassembly.”

There has been a major shift from metal to resins in gasket manufacturing. Gaskets can be made from Ultem®, Ryton PPS and Fluoropolymers (PFA plastic) because of high heat resistance, chemical resistance, and ability to mold thin walls (.012”). Plastic parts may also lower the cost of production of batteries and may eventually replace most metallic components of batteries.

Performance Plastics is highly skilled at designing and molding high performance materials such as FEP/PFA, 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]

 

 

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What is PFA and What Is It Used For?

September 21, 2021  |  , , , ,

PFA plastic (perfluoroalkoxy) is a tough, flexible fluoropolymer that is used for flexible and reusable medical equipment pharmaceutical and semi-con devices when chemical resistance, high purity, and flexibility are required.

PFA plastic is generally used for medical, pharmaceutical and semi-conductor plastics due to its extreme resistance to chemical attack, optical transparency, and overall flexibility. Keeping material purity is of critical importance in most injection molding applications, but particularly the medical, pharmaceutical and semi-conductor industries.

Devices used for medical, pharmaceutical measurement and semi-conductor are frequently exposed to harsh biological and chemical elements. Parts manufactured or coated in PFA materials provide good resistance and are an effective solution for avoiding contamination.

PFA is such an optimal material, that in some cases it can even replace stainless steel in medical devices.   PFA handles high temperatures and pressure well and is resistant to biological impurities. PFA is a go-to option for moving elements in medical devices because of its stiffness and long life, while providing flexibility and resistance to cracks

Many PFAs are used in pharmaceutical industry because of mandated regulations for process component materials. PFA is very versatile in how parts can be manufactured, and it lends itself well to extrusion, injection molding, transfer molding,  blow molding and compression molding.  You will often see PFA in lab equipment because of its outstanding chemical inertness and flexibility.

PFA resins are fully fluorinated polymers specifically designed for the high demanding applications of the semi-con industry.  The high purity composition of PFA addresses the requirement for minimum extractables while proving improved flex life and excellent chemical stress crack resistance.

PFA Properties

  • Chemically stable
  • Dielectric strength
  • Non-flammable
  • Chemical resistance
  • Anti-stick properties
  • Low friction
  • FDA approved
  • High purity
  • UV Resistant
  • Translucent
  • Low moisture absorption

PFA is one of the many advanced fluoropolymers Performance Plastics can mold within extremely tight tolerances.  For more information, please contact Rich Reed, Vice President of sales and marketing at 513.321.8404 or [email protected].

 

 

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Performance Plastics – Specialists in Metal to Plastic Conversion

August 26, 2021  |  , , ,
carbon fiber filled PEEK thermoplastic gear

Proprietary impregnated PEEK distributor gear for improved performance and useful life

Metals have been the first choice of design engineers for almost three centuries. Developments in highly engineered thermoplastics materials are challenging that dominance. The aerospace and automotive industries have led the charge in this dramatic changeover, initially driven by the need to reduce weight to gain fuel efficiency. Advanced thermoplastic and thermoset systems, including fiber reinforced compositions, are now finding their way into almost every industry.
PEEK is a mainstay material for a growing variety of applications in many different industries. Its popularity is due to excellent friction and wear characteristics, extended durability under punishing environmental conditions, including high temperatures, abrasion and aggressive chemical environments.

Unfilled PEEK resins emit extremely low levels of smoke and toxic gas when exposed to a flame. Glass and carbon reinforced PEEK resins offer high thermal stability and are among the strongest thermoplastics in the market.
PEEK has a long list of outstanding characteristics making it one of the most popular alternatives to metal:

• High mechanical strength and dimensional stability
• Excellent resistance to harsh chemicals
• High wear resistance
• Low coefficient of friction; high abrasion and cut-through resistance
• Excellent performance at high temperatures

Performance Plastics uses various grades of PEEK resin as metal replacements in applications where few other fluoropolymers would be considered. PEEK is widely used in industries such as: aerospace (commercial and defense), automotive, marine, industrial and energy (fossil fuel and renewable). To discover how PEEK polymer resins can make the transition from metal to thermoplastic easier, please visit our website at https://performanceplastics.com/capabilities/polymer-seals or contact Rich Reed, Vice President of Sales and Marketing, at (513) 321-8404 or [email protected]

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Injection Molded Peek Seals

July 21, 2021  |  , , , , , ,

Performance Plastics offers the expertise and technology to produce net shape seals in high-performance materials such as PEEK.  PEEK (polyetheretherketone) polymer is a high-performance thermoplastic material with outstanding mechanical, thermal and chemical resistance properties

Seals have been used since ancient times and have evolved into a wide variety of shapes and materials. Mechanical seals are used to seal the openings of and joints between mechanisms to contain pressure and form a barrier to prevent the fluid (water or oil) used by a machine from leaking to the external environment.  Commonly used in pumps, motors, and compressors, seals are one of the most essential components to ensure a machine operates reliably and effectively.

PEEK is an organic thermoplastic polymer that offers excellent mechanical and chemical resistance properties for applications that are maintained at high temperatures. PEEK seals can be heated, cooled, and heated again without degradation since they are composed of thermoplastic materials.

PEEK polymer seals are well suited for demanding applications such as aerospace, automotive, and medical because of their robustness. They offer outstanding chemical resistance over a wide range of temperatures and are an excellent option for extreme applications where failure is not an option.  Performance Plastics’ team of experienced engineers possess the expertise to design technically challenging seals and offer complex solutions across a wide range of industries.

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

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Performance Plastics – Experts in Molding High Performance Plastics – Torlon®

May 12, 2021  |  , , , , , ,

Performance Plastics specializes in precision injection molding of high-performance plastics. Our precise production process gives us the ability to injection mold difficult polymers, producing high quality thermoplastic products.

High performance plastic materials, such as PAI (Polyamidimide) Torlon®, possess ideal properties when it comes to molding for strength and durability. Recognized as one of the highest performing thermoplastic materials, Torlon® exhibits greater compressive strength and impact resistance than other high-performance plastics. Torlon’s high creep resistance and extremely low coefficient of linear thermal expansion (CLTE) provides excellent thermal stability. This provides for creating manufactured parts that exhibit high levels of tensile strength, friction wear, compression strength, and rigidity, ensuring exceptional mechanical loading capabilities up to 525°F (275°C).

At Performance Plastics, we are experts in injection molding, specializing in high performance plastics. High performance plastics, such as Torlon®, can be extremely difficult to injection mold due to the polymers unique structure. Torlon® is a reactive polymer, 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 Torlon®. Our proprietary tool design software, processes and equipment enables us to injection mold components having complex geometries made from challenging ultra, high-performance thermoplastic materials and reinforced 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. Our expertise in process control allows us to effectively injection mold Torlon® in parts with extremely tight tolerances. This gives us the ability to provide you with an injection molded part made from the highest strength and stiffness of any commercial thermoplastic.

Torlon® is one of the many high performance polymers Performance Plastics offers.  For more information on Performance Plastic’s capabilities, please contact Rich Reed, our Vice President of Sales and Marketing at 513.321.8404 or email at [email protected].

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