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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The Importance of FEP/PFA for the Energy Storage Function of Batteries

November 9, 2023  |  , ,

Fluorinated ethylene propylene (FEP) and perfluoroalkoxy (PFA) are fluoropolymer materials that are often used in the construction of certain components in batteries, particularly as insulating materials. While they may not directly store energy in batteries, they play a crucial role in enhancing the safety, efficiency, and performance of battery systems. Here’s why FEP/PFA plastics are important for the energy storage function of batteries:

 

  1. Chemical Resistance: FEP and PFA plastics are highly chemically resistant, which is crucial in battery applications. They can withstand exposure to various corrosive electrolytes and chemicals found within batteries without degrading or reacting. This resistance helps ensure the long-term stability and integrity of the battery components, leading to improved battery durability and lifespan.
  2. Thermal Stability: FEP and PFA materials have excellent thermal stability and can withstand a wide range of temperatures, from extremely cold to very hot conditions. This property is essential for batteries, as they can operate in environments with varying temperature conditions. Maintaining thermal stability helps to prevent short circuits, leakage, and overall performance issues.
  3. Dielectric Properties: Both FEP and PFA injection molded parts are excellent electrical insulators. They have a low dielectric constant and low dissipation factor, meaning they have the ability to insulate and isolate electrical components in batteries effectively. This is vital for preventing short circuits and ensuring the safe operation of the battery.
  4. Low Permeability: FEP and PFA plastics have low gas and liquid permeability, which is essential for battery separators. The separators in batteries are critical for preventing direct contact between the positive and negative electrodes, while still allowing the passage of ions. Low permeability materials help maintain this separation, preventing electrolyte leakage and maintaining the battery’s overall performance.
  5. Mechanical Strength: FEP and PFA injection molded materials are durable and mechanically robust. They can withstand mechanical stresses and pressure changes that batteries may experience during manufacturing, assembly, and use. This strength is particularly important for maintaining the integrity of battery components and preventing damage.
  6. Non-reactive Nature: FEP and PFA are non-reactive with most substances, which is essential for ensuring the purity of the battery components. They do not react with the electrolyte or other battery materials, helping to maintain the chemical stability of the battery system.

While injection molded FEP and PFA plastics do not store energy in batteries themselves, they are crucial components for ensuring the safe and efficient operation of battery systems. Their chemical resistance, thermal stability, dielectric properties, low permeability, mechanical strength, and non-reactive nature all contribute to the overall performance, safety, and longevity of energy storage systems, making them indispensable for the function of batteries in various applications. For more information on FEP and PFA plastics for batteries, please call Rich Reed, Vice President of Sales and Marketing at 440-785-7122.

 

 

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Fluoropolymers are a great choice for Challenging Environments

October 26, 2023  |  , ,

Fluoropolymers are indeed an excellent choice for parts that must perform in challenging environments. These polymers, which include materials like PTFE (polytetrafluoroethylene), FEP (fluorinated ethylene propylene), and PFA (perfluoroalkoxy), offer a range of unique properties that make them ideal for such applications:

  1. Chemical Resistance: Fluoropolymers are highly resistant to a wide range of corrosive chemicals, acids, and bases. This makes them suitable for use in environments where other materials would quickly deteriorate or corrode.
  2. Temperature Resistance: These polymers can withstand extreme temperatures, both high and low. PTFE, for example, can handle temperatures as low as -200°C and as high as 260°C, making it ideal for applications in harsh temperature conditions.
  3. Non-Stick Properties: Fluoropolymers have excellent non-stick properties, which means they do not easily adhere to other materials. This is why they are often used in cookware coatings, but it’s also valuable in industrial applications where materials need to slide or not adhere to surfaces.
  4. Electrical Insulation: They have good electrical insulation properties, which is important in applications where electrical conductivity could cause problems.
  5. UV Resistance: Many fluoropolymers are highly resistant to ultraviolet (UV) radiation, making them suitable for outdoor applications.
  6. Low Friction Coefficient: These materials have a low coefficient of friction, which means they can reduce wear and tear in moving parts and machinery.
  7. Biocompatibility: Some fluoropolymers are biocompatible, making them suitable for use in medical and pharmaceutical applications.

Fluoropolymers find applications in various industries, including chemical processing, electronics, aerospace, and automotive, where they are exposed to aggressive chemicals, extreme temperatures, and other challenging conditions. Their durability, resistance, and performance characteristics make them an excellent choice for parts and components in these demanding environments.

For more information on how Performance Plastics can help you with your material choice in challenging environments, please contact Rich Reed, Vice President of Sales and Marketing at [email protected]

 

 

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High-Performance Polymers for Medical Devices

October 12, 2023  |  , , ,
Thermoplastic injection molded PEEK Medical Tool

Thermoplastic Injection Molded PEEK Medical Device

High-performance polymers have gained significant attention in the field of medical devices due to their unique properties and advantages. These materials offer a compelling alternative to traditional materials like metals and ceramics in various medical applications. Here are some reasons why high-performance polymers are a great alternative for medical devices:

  1. Biocompatibility: High-performance polymers, such as PEEK, FEP, PFA, and PPSU, are inherently biocompatible. They do not trigger adverse immune responses or toxicity when in contact with biological tissues, making them suitable for implants and other medical devices that interact with the human body.
  2. Lightweight: Polymers are generally lighter than metals, making them ideal for applications where weight reduction is critical, such as orthopedic implants and prosthetics. Lighter devices can improve patient comfort and reduce the risk of complications.
  3. Corrosion Resistance: High-performance polymers are highly resistant to corrosion and chemical degradation. This property is advantageous in medical devices that come into contact with bodily fluids and other aggressive environments. Unlike metals, they do not rust or corrode.
  4. Radiolucency: Some polymers, like PEEK, are radiolucent, meaning they do not block X-rays or other imaging techniques. This feature allows for clear and accurate imaging of the surrounding tissue and device placement without interference.
  5. Customizability: Polymers can be easily molded and machined into complex shapes, which is crucial for designing patient-specific implants and devices. This customizability can improve the fit and function of medical devices.
  6. Low Friction and Wear Resistance: Polymers can offer low friction and wear characteristics, making them suitable for articulating joints and moving parts in medical devices. This reduces the risk of device failure and the need for frequent replacements.
  7. Electrical Insulation: High-performance polymers are electrical insulators, which is essential in devices like pacemakers and neurostimulators to prevent unwanted electrical interference with surrounding tissues.
  8. Thermal Stability: Many high-performance polymers exhibit excellent thermal stability, allowing them to withstand sterilization processes such as autoclaving without degradation.
  9. Cost-Effective: Compared to some specialty metals and ceramics, high-performance polymers can be more cost-effective, making medical devices more affordable for healthcare providers and patients.
  10. Regulatory Approval: Several high-performance polymers have received regulatory approval for use in medical devices, indicating their safety and suitability for these applications.

Despite their numerous advantages, high-performance polymers also have limitations, including lower strength and stiffness compared to some metals and ceramics. Therefore, their selection for specific medical device applications should consider the specific requirements and constraints of the device.

In conclusion, high-performance polymers offer a compelling alternative for medical devices due to their biocompatibility, lightweight nature, corrosion resistance, customizability, and other favorable properties. As materials science continues to advance, it is likely that high-performance polymers will play an increasingly significant role in the development of innovative medical devices.

For more information on polymers for medical devices and how Performance Plastics leverages their use, please contact Rich Reed, Vice President of Sales and Marketing at [email protected].

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Injection Molded PFA for Semiconductor Applications

October 5, 2023  |  , ,

PFA or high-purity perfluoroalkoxy is a high-performance material ideal for the semiconductor industry due to its excellent chemical resistance, high-temperature stability, and electrical insulating properties. These characteristics make it suitable for use in extreme conditions. However, it’s important to ensure that the PFA material meets specific semiconductor requirements.

Here are some factors to consider when using injection-molded PFA in semiconductor applications:

  1. Purity: Semiconductor manufacturing requires extremely high levels of material purity to prevent contamination. Ensure that the PFA material used in injection molding meets the purity standards required for semiconductor processes.
  2. Temperature Resistance: Semiconductor processes often involve high temperatures. PFA has a high melting point and can withstand elevated temperatures, making it suitable for many semiconductor applications.
  3. Chemical Compatibility: PFA is highly resistant to a wide range of chemicals, which is advantageous in semiconductor processing where various chemicals are used. Ensure that the PFA material is compatible with the specific chemicals and processes in your semiconductor application.
  4. Electrical Insulation: PFA is an excellent electrical insulator, which is important in semiconductor equipment and components where electrical isolation is required.
  5. Surface Finish: The surface finish of injection molded PFA components should meet the cleanliness and smoothness requirements of the semiconductor industry to minimize the risk of particle contamination.
  6. Dimensional Accuracy: Precision and tight tolerances are often required in semiconductor equipment. Injection molding can achieve high levels of dimensional accuracy, but it’s crucial to ensure that the molded parts meet the required specifications.
  7. Compliance with Standards: Ensure that the PFA material and injection molding processes used comply with relevant industry standards and regulations in the semiconductor sector.
  8. Testing and Validation: Conduct rigorous testing and validation of PFA components in your semiconductor application to ensure their performance under actual operating conditions.

It’s important to work with an experienced manufacturer, such as Performance Plastics, who understands the specific requirements of the semiconductor industry. Our engineers can help you choose the right PFA material, design components to meet your needs and ensure that the injection molding process meets the strict semiconductor industry standards.

For more information on how Performance Plastics can help with your semi-conductor project, please contact Rich Reed, Vice President of Sales and Marketing at 440-785-7122 or email at [email protected]

 

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The Benefits of FEP and PFA Conductive Polymers

September 28, 2023  |  ,

Conductive polymers such as FEP and PFA are a class of materials that exhibit electrical conductivity while maintaining the mechanical properties and processability of traditional polymers. These materials have garnered significant attention and research interest due to their unique combination of properties, which offer a wide range of potential applications. Here are some of the benefits of conductive polymers:

  1. Electrical Conductivity: Conductive polymers can conduct electricity, making them suitable for various electronic and electrical applications. Unlike traditional insulating polymers, which do not conduct electricity, conductive polymers can carry electrical currents.
  2. Lightweight and Flexible: Conductive polymers are lightweight and flexible, which makes them ideal for applications where traditional conductive materials like metals would be impractical due to their weight or lack of flexibility. This property is particularly advantageous in wearable electronics, flexible displays, and flexible sensors.
  3. Processability: Conductive polymers can be processed using conventional polymer processing techniques, such as injection molding. This ease of processing allows for the production of complex shapes and making them versatile materials for various applications.
  4. Corrosion Resistance: Unlike metals, conductive polymers are generally corrosion-resistant, making them suitable for use in harsh environments, such as marine or chemical processing applications.
  5. Biocompatibility: Some conductive polymers are biocompatible, which means they can be used in medical devices, implantable electronics, and tissue engineering applications without causing harm to living tissues.
  6. Low Cost: Conductive polymers are often more cost-effective than traditional conductive materials like metals or semiconductors. This cost advantage can make them attractive for large-scale applications.
  7. Energy Storage: Conductive polymers are used in energy storage devices, such as supercapacitors and batteries, due to their ability to store and release electrical energy efficiently.
  8. Sensors and Actuators: They are used in various sensor and actuator applications, including chemical sensors, gas sensors, strain sensors, and smart materials that can change shape or properties in response to electrical stimuli.

While conductive polymers offer many advantages, they also have some limitations, such as lower electrical conductivity compared to metals and sensitivity to environmental factors like moisture and oxygen.

For more information on electrically conductive materials and how Performance Plastics leverages their use, please contact Rich Reed, Vice President of Sales & Marketing at 440-785-7122 or [email protected]

 

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Why Use a High-Performance Plastic for your Gasket?

March 28, 2023  |  , , ,

A high-performance plastic is a resin that exhibits characteristics that make it a viable alternative to metals for use in industrial applications.  Characteristics include strength & durability, temperature resistance, electrical properties, lightweight, and versatility.  Overall, high-performance plastics can be custom designed to meet specific performance criteria and offer a wide range of benefits.

A gasket is a mechanical seal that fills the space between two or more mating surfaces to prevent leakage from or into joined objects under compression.  They extend the lifespan of moving parts by protecting against rubbing or friction.  Today, high-performance plastic gaskets are used as an alternative to metal gaskets as they offer great durability and corrosion resistance.  They are also lightweight, have low friction, and have good sealing and insulation properties.

The benefits of using a gasket made of high-performance plastics include:

  • Improved functionality and performance
  • Improved resistance to many chemicals
  • Improvement in vibration
  • Improved handling of temperature fluctuation
  • Improved impact resistance

High-performance plastic gaskets can be custom designed to meet specific performance criteria and offer a wide range of benefits depending on the application.

Performance Plastics has over 40 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 on high-performance plastic gaskets or other Performance Plastics’ services, please contact Rich Reed, Vice President of Sales & Marketing at 440-785-7122.

 

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What You Don’t Know About FEP/PFA Injection Mold is Costing You Money

December 7, 2022  |  , , ,

A fluoropolymer is one of the growing numbers fluorocarbon-based polymers. They are widely used in healthcare applications due to their biocompatibility, lubricity, sterilizability, chemical inertness, thermal stability, barrier properties, and high purity. However, when compared with other resins, they are significantly more expensive and require special techniques to injection mold due to their shear sensitivity, high melt temperatures, and fluorine outgassing when melted.

Although the best-known fluoropolymer, polytetrafluoroethylene (PTFE or Teflon®), has been on the market since the 1940s, newer resins have been developed to address specific injection molding niches. Perfluoroalkoxy polymer (PFA) and fluorinated ethylene-propylene (FEP plastic) are among the most recent additions to the list of fluoropolymer options.

PFA was developed in order to create a true melt-processable fluoropolymer. It provides the smoothest and least wettable finish of all of the fluoropolymers. Its optical transparency, chemical inertness, and overall flexibility have made it popular for use in lab equipment. It also has superior electrical properties, with dielectric strength that’s three to four times greater than PTFE can offer.

Like PFA, FEP is melt-processable and injection moldable. Its melting point of 260 °C (500 °F) is about 40 degrees lower than PFA’s.  It offers low friction and chemical inertness properties comparable to PTFE’s. However, it is completely transparent. Because FEP is highly resistant to sunlight, it is especially useful for molding parts that are subjected to weathering.

However, not all injection molders are equipped to work with fluoropolymers like PFA and FEP. Performance Plastics LTD. has developed a variety of tools and procedures to address the challenges involved in molding these materials. For example, our solution includes a hot runner system and mold designed to minimize the shear forces inherent in the injection molding process. We use proprietary metallurgy that’s highly resistant to fluorine gas corrosion, which helps extend the working life of the hot runner system, tooling and other components that make contact with the melted resin. We’ve also developed a direct-gating, multi-runner approach to tool design that eliminates the sprue and runner used in traditional injection molding. By eliminating the wasted material associated with the sprue and runner, Performance Plastics has been able to pass along material cost savings of from 20% to 40% by using these expensive resins more economically.

To learn more about how we can cut your resin costs while helping you take advantage of the unique properties PFA and FEP offer, visit our contact page or contact Rich Reed, our vice president of sales and marketing, at (513) 321-8404 or [email protected].

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Fluoropolymers may be the solution to the Medical Glass Shortage

November 10, 2022  |  , , , ,

The shortage of glass has been an ongoing issue. Experts say the price of glass is on the rise as global supply chain issues continue throughout the world.  The glass shortage affects all industries that rely on glass for their containers, but right now, with the convergence of annual flu, the emergence of new COVID variants (Omicron), and the outbreak of Respiratory Syncytial Virus Infection (RSV) in children, the medical field is in dire need of glass for vials.

Silicon, which is one of the materials that is used in glass manufacturing has been in short supply for over a year.  Medical vials are made of Type I borosilicate glass, and this form uses the most silicon. The decreases in the recycling rates during the pandemic, are additionally hurting the production of glass vials.

Fluoropolymers such as FEP, PFA, and PCTFE are great alternative materials for glass. These fluoropolymers are superior to conventional plastics. Their inert, non-reactive, and unmatched durability makes their properties ideal for use in the medical industry. These fluoropolymers are also non-stick, ensuring the product does not adsorb to surfaces. They are also virtually impervious to chemical, enzyme, and microbiological attacks. All the benefits of FEP, PFA, and PCTFE make these fluoropolymers a perfect material to create vials out of, especially since they are injection moldable.

At Performance Plastics, we have extensive experience in injection molding fluoropolymers. We have developed proprietary tooling and processes enabling the injection molding of small, thin-walled, complex parts. Our expertise in fluoropolymers and injection molding can be the solution to the shortage of glass.

For more information on how to use fluoropolymers as your glass shortage solution contact Rich Reed, our Vice President of Sales and Marketing, at (513) 321-8404 or [email protected].

 

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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) 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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