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 RReed@performanceplastics.com.

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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 RReed@performanceplastics.com.

 

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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 RReed@performanceplastics.com.

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FEP Uses in Semiconductor Manufacturing

September 6, 2022  |  , , ,

Fluorinated ethylene propylene (FEP) is a copolymer of hexafluoropropylene and tetrafluoro ethylene that is chemically resistant, electrically stable, insulating and possesses useful low shielding properties.  It is easily formable and was developed as a melt processable material.

Semiconductors are the brains of electronics, enabling advances in countless applications and emerging technologies. The application of semiconductor devices can be found in almost every technology today, ranging from cars, phones, computers and much more. The manufacturing of semiconductors and semi-conductor related products require reliable, high purity materials that can survive harsh operating conditions.  The correct solution can increase production efficiency, reduce power requirements and increase process reliability.

FEP coatings are well suited for applications in the semiconductor industry where they are used in the manufacture of wafer carriers, sensors, seals, fittings and pump parts which are optimal for transporting high-purity chemicals in semiconductor manufacturing.

Key Material Properties for Semiconductor Applications

  • Reliable mechanical performance
  • Low levels of total organic carbon
  • High performance in pure deionized water
  • Low permeation rates
  • Resistance to both dry and wet process

For more information on FEP uses in Semiconductor manufacturing, please contact Rich Reed, Vice President of Sales & Marketing at 513.321.8404 or rreed@performanceplastics.com

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Types of Plastics used in the Semiconductor Industry

August 23, 2022  |  , , , ,

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

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

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

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

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

 

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

 

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

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

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Injection Molded PFA for Semicon Meets F-57 Requirements

August 2, 2022  |  , , ,

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

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

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

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

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

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

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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 rreed@performanceplastics.com.

 

 

PFA plastic (Fluoropolymer) Thermoplastic Components

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Fluoropolymers Are A Great Choice For Parts That Must Perform In Unique Conditions

May 19, 2022  |  , , ,

When you need parts that can withstand extreme operating conditions, fluoropolymers may fit the bill. Parts like roofing membranes, fuel tubes, biomedical devices, and wires are all common applications of fluoropolymers.

FEP Fluoropolymer:

Fluorinated ethylene propylene (FEP resin) is a melt-processable fluoropolymer. FEP has low gas and permeability properties, can be extruded in long continuous lengths, and possesses excellent UV transmission rating. FEP is also suitable for use in a biomedical setting and is gamma sterilizable.

All of these attributes make FEP an ideal fluoropolymer for a diverse range of applications from environmental monitoring equipment to medical devices and electronics. Because it is a thermoplastic, FEP is also easily heat-formed, tipped, tapered, flared, and flanged.

PFA Fluoropolymer:

Perfluoroalkoxy (PFA resin) is a melt-processable fluoropolymer that combines many of the best traits of PTFE and FEP. At 500 °F (260 °C), PFA has a higher service temperature than FEP and maintains its mechanical integrity in extreme temperatures even when exposed to caustic chemicals. PFA has greater tensile strength than PTFE and a smoother surface finish than both PTFE and FEP.

PFA’s is a top choice in semiconductor, chemical, oil and gas, aerospace, automotive, pharmaceutical, and medical industries. This fluoropolymer has excellent lubricity, clarity, flexibility, and chemical resistance, making it a versatile choice.

FEP vs PFA Fluoropolymers

FEP and PFA are injection moldable, highly inert, compatible with most organic compounds, have good barrier properties and high continuous use temperatures. They are virtually impervious to chemical, enzyme and microbiological attack and stiffer than PTFE. The non-stick properties of these polymers can also be useful to reduce liquid, gel and powder adhesion. Fluoropolymers in general, have good dielectric properties and are resistant to atmospheric degradation.
While significantly less expensive than PFA, FEP is very difficult to mold due to its low viscosity. However, Performance Plastics has developed proprietary tooling and processes enabling the injection molding of small, thin-walled, complex FEP parts.

• More transparent than PTFE (not injection moldable)

• Better gas and vapor permeability properties than PTFE
• Maximum working temperature 400°F
• Approximately 1/3 the cost of PFA

PFA is significantly easier to mold than FEP, however, it is significantly more expensive.

• Higher continuous service temperature than FEP
• Maximum working temperature 500°F
• Difference in molecular structure gives PFA improved flow, creep resistance and thermal stability.

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 rreed@performanceplastics.com

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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 rreed@performanceplastics.com

 

 

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