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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Process Monitoring is Crucial in Tight Tolerance HPM Plastic Injection

September 7, 2023  |  , ,

Plastic Injection Molding HPM (high-performance material) parts with tight tolerances demand that processes are repeatable within established limits.  Performance Plastics utilizes best practices to eliminate process inefficiencies and unplanned maintenance, when working with materials such as Torlon (PAI), PEEK, Ultem (PEI) and FEP/PFA.  Simple processes must take place every shift to ensure that process and production are on target.

  • Process Validation

Process validation procedures must be completed prior to establishing process monitoring.  A validated process must run at complete cycle efficiency, producing little to no scrap for no less than 8 hours.  Evaluations and considerations must be analyzed whether a process can be repeated from one run to the next.

  • Process Installation Qualification – Making Sure Everything Works
  • Operational Qualification – Test, Test, and Test Again
  • Performance Qualification – Testing the actual Part.
  • Process Monitoring

Many companies fail to understand that a similar press or mold does not guarantee the tight tolerance processes will be repeated, especially when working with HPMs.  Each press must have its own process monitoring record, and sister molds need to be approached as completely different molds.

Areas that must be constantly monitored:

  • Fill Time
  • Peak Pressure
  • Part Weight
  • Cycle

Each value must have control limits and must be within the window established for these limits to control.

  • Basic Molding Fundamentals

The key to the HPM process consistency is the care and inspection of molds before each job.

  • Molds are cleaned and inspected.
  • Nozzles are inspected for blowback.
  • Hot runner point temperatures are verified.
  • Water is verified at the beginning of each run.

Performance Plastics embraces best practices in order to provide our customers with the quality and repeatability required for HPM tight tolerance medical, aerospace, and industrial parts.

For more information on how Performance Plastics manages our best practices, please contact Rich Reed, Vice President of Sales and Marketing at [email protected], or visit our website and www.performanceplastics.com

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Performance Plastics – PEEK use in Medical Devices

June 22, 2023  |  ,

PEEK Resin Thermoplastic Component

Engineered Plastic Medical Devices are revolutionizing the healthcare industry. The growth of polymers has transformed the marketplace, with plastic medical devices steadily replacing other materials such as glass, ceramics, and metals, wherever applicable.

Peek (Polyether Ether Ketone) plastics are widely used in the medical device industry due to their excellent mechanical properties, biocompatibility, and resistance to chemicals and high temperatures. Here are some ways Peek plastics are used in medical devices:

  1. Implants: Peek is commonly used in orthopedic implants, such as spinal fusion cages, joint replacements, and trauma fixation plates. Its mechanical properties closely resemble those of bone, making it an ideal material for load-bearing applications. Peek’s biocompatibility allows it to integrate well with the surrounding tissue.
  2. Dental Applications: Peek is used in dental applications like dental implants, temporary crowns and bridges, orthodontic brackets, and dental surgical instruments. It provides good strength and stability, and its tooth-colored variants offer aesthetic benefits.
  3. Surgical Instruments: Peek is utilized in the manufacturing of surgical instruments, including forceps, retractors, and endoscopic components. Its high strength, durability, and resistance to sterilization methods such as autoclaving make it suitable for repeated use.
  4. Medical Device Housings: Peek is used for the housing and structural components of various medical devices, such as handheld surgical tools, electronic devices, and monitoring equipment. Its mechanical strength, resistance to sterilization, and biocompatibility make it suitable for these applications.
  5. Ophthalmic Devices: Peek is used in the manufacture of intraocular lenses (IOLs), which are artificial lenses implanted in the eye during cataract surgery. Peek’s optical clarity, biocompatibility, and resistance to degradation within the eye make it a preferred material for IOLs.

Peek plastics offer several advantages for medical devices, including their radiolucency (compatibility with X-rays), high strength-to-weight ratio, chemical resistance, and biocompatibility. These properties make Peek a versatile and reliable material choice in various medical applications.

For more information on PEEK and its use in medical applications, please contact Rich Reed, Vice President of Sales & Marketing at [email protected], or visit our website at www.performanceplastics.com.

 

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Endurosharp® Torlon® Tools vs Traditional Metal Scrapers

June 15, 2023  |  , ,

Correctly and efficiently performing aircraft maintenance requires the correct tools.  Patented EnduroSharp® Torlon® aircraft maintenance tools, exclusively from Performance Plastics, are the correct tools.  They are non-metallic scraper tools that quickly and effectively remove silicone, sealants, adhesives, and coatings while keeping an effective edge and not damaging underlying materials.

At the time of development, many nonmetallic scrapers were available and approved for various material removal applications. But, the effectiveness of the existing tools varied, and the tools were generally inefficient & short-lived. Some even pose a great risk to the underlying structures.

Under contract with the Air Force Research Laboratory’s Materials Integrity Branch (AFRL/RXSA), the University of Dayton Research Institute (UDRI) developed the EnduroSharp® line of Torlon® material removal tools.

After sampling available tools on the market for material and design, the material Torlon® by Solvay was chosen, along with a spiral-fluted design for the GFR Bit. Torlon® is a polyamide-imide (PAI) resin that is a high-end niche material that proved to be ideal for the application.  Initially, three types of tools were developed:

  • Gap Filler Removal Bits (GFR Bit)
  • Torlon Scraper Blade (TSB)
  • Torlon Gap Blade (TGB)

All three tools were extensively tested and summarized. It was concluded that Torlon® was indeed a great material for the application.  The material offered significantly less damage potential than other often-used tools.  It offered faster material removal rates and required less operator effort.  Additionally, the material proved to be resharpenable.

At the request of our users, EnduroSharp® is soon to release our new TSR Cutter, The Torlon Sealant Remover Cutter (TSR) is a rotary cutter designed to safely remove thick layers of sealants and adhesives from larger areas, such as fuel cells, without damaging the underlying coatings and surfaces.

The EnduroSharp® line is offered by over 100 organizations and is under evaluation for 11 weapons systems at 10 DoD locations.

For more information on the EnduroSharp® line of products, please contact Rich Reed, Vice President of Sales & Marketing at [email protected], or visit our website at www.performanceplastics.com.

 

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Performance Plastics – Experts in Micro Molding Technology

June 6, 2023  |  , ,

 

Micro injection molding is a specialized form of injection molding that is used to produce small, intricate parts with high precision and accuracy, It has gained significant attention in various industries, including medical devices, electronics, automotive, and aerospace/defense.  In recent years, several innovations have emerged in micro injection molding, improving its capabilities, and expanding its applications.

  • Advanced Tooling: Innovations in micro injection molding tooling have significantly contributed to improved part quality and increased production efficiency. High-precision molds with complex geometries and tight tolerances can now be manufactured using advanced machining techniques like micro-milling and electrical discharge machining (EDM). These techniques enable the creation of intricate features and microstructures in molds, producing highly detailed micro parts.
  • Material Selection: Micro injection molding has benefited from the development of new materials specifically designed for small-scale molding. These materials offer enhanced flow properties, dimensional stability, and improved mechanical properties. They include specialized engineering plastics such as high-temperature thermoplastics. The availability of a broader range of materials expands the potential applications of micro injection molding.
  • Process Monitoring and Control: The integration of advanced sensors and monitoring systems has improved the control and consistency of the micro injection molding process. Real-time monitoring of key process parameters, such as temperature, pressure, and flow rate, allows for better process optimization and early detection of issues. Closed-loop feedback systems can automatically adjust process parameters to maintain consistent part quality, reducing scrap rates and improving overall productivity.
  • Microfluidic Devices: Micro injection molding has found extensive use in the production of microfluidic devices, which are used in applications like medical diagnostics, chemical analysis, and drug delivery systems. Innovations in microfluidic design and fabrication techniques have enabled the integration of complex fluid channels, valves, and sensors into small, disposable devices. Micro injection molding provides a cost-effective and scalable manufacturing method for producing these devices with high precision and reproducibility.
  • Multi-Material and Overmolding: Recent innovations in micro injection molding have focused on enabling multi-material molding and over-molding processes. Multi-material molding allows for the integration of different materials or colors within a single micro part, expanding design possibilities and functionality. Overmolding, on the other hand, involves molding one material over another, creating bonded layers or adding soft-touch grips to parts. These capabilities enhance the versatility and aesthetics of micro-injection molded products.
  • These innovations in micro injection molding have expanded its capabilities, enabling the production of smaller, more complex parts with improved quality and functionality.

Micro injection molding is widely applied for parts and devices in medical, pharmaceutical, electronics, automotive, optical, and other industries. In general, the medical micro injection molding market is the leading one, due to an increase in the usage of sophisticated micro components for endoscopic surgery, minimally invasive treatments, and other advanced technology developments.

Performance Plastics are experts in precision injection molding.  We have developed proprietary tooling, unique metallurgy equipment, and processes that produce custom-molded plastics such as fluoropolymers, Ultem®, PEEK, and Torlon®.  We leverage our high-performance polymer expertise and technology to develop thermoplastic compounds and techniques to deliver the best possible results on our projects.

For more information on how micro molding can benefit your application, please contact Rich Reed, Vice President of Sales & Marketing at [email protected] or visit our website at www.performanceplastics.com.

 

 

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Performance Plastics – Family Molds for Advanced Materials

June 1, 2023  |  , , ,

Family_Mold

A family mold is a mold that produces different parts using the same base.  There can be multiple cavities for different part numbers.  Family molds often have a building cost advantage over molds dedicated to a single part number.

A common usage is to combine two halves of housing into a family mold. Halves are purchased in sets which makes running them together a good option.  They don’t have to be run together, so a shut-off runner must be included which allows one or more cavities to be turned off during production.

Family molds are often more practical than dedicated molds with moderate production volumes, whereas dedicated multiple cavities would be more expensive.  But family mold layout design is demanding and requires experience when dealing with advanced materials.

There are big differences between the properties, processing methods, and applications of various advanced materials.  Engineers need to understand the properties of the materials when using a family mold.  All advanced materials have benefits and deficiencies, so this understanding is key to the success of a project.

The conditions encountered when forcing molten plastic through a mold’s sprues, runners, and gate change as the mold becomes larger, and more complex, which impacts the molding process and material quality.  Thermal variations within a family mold become more of a concern, increasing the risk of partially filled cavities as well as part deformation.

Performance Plastics are experts in precision injection molding.  We have developed proprietary tooling, unique metallurgy equipment, and processes that produce custom-molded plastics such as fluoropolymers, Ultem®, PEEK, and Torlon®.  We leverage our high-performance polymer expertise and technology to develop thermoplastic compounds and techniques to maximize your family mold and provide the best quality on your mold investment.

For more information on family molds and how they can benefit your application, please contact Rich Reed, Vice President of Sales & Marketing at [email protected] or visit our website at www.performanceplastics.com.

 

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Torlon for Precision Industrial Applications

May 18, 2023  |  , , ,

Torlon is a high-performance polymer that is often used in precision industrial applications due to its exceptional mechanical and thermal properties. It is a brand name for polyamide-imide (PAI), a thermoplastic material that exhibits excellent strength, stiffness, and dimensional stability.

Here are some key characteristics and advantages of Torlon in precision industrial applications:

  1. High Strength and Stiffness: Torlon has a high strength-to-weight ratio and exceptional rigidity, making it suitable for applications that require structural integrity and resistance to deformation under heavy loads.
  2. Dimensional Stability: Torlon maintains its dimensional stability even under elevated temperatures, which is crucial in precision applications where tight tolerances and accurate fit are required. It has a low coefficient of thermal expansion, reducing the risk of dimensional changes due to temperature fluctuations.
  3. Chemical Resistance: Torlon is highly resistant to a wide range of chemicals, including acids, solvents, fuels, and oils. This chemical resistance makes it suitable for applications in chemical processing, oil and gas, and other industries where exposure to corrosive substances is a concern.
  4. High-Temperature Resistance: Torlon retains its mechanical properties at elevated temperatures, with a glass transition temperature (Tg) of approximately 280°C (536°F) and a melting point of around 310°C (590°F). This thermal stability allows it to perform reliably in high-temperature environments.
  5. Low Friction and Wear Resistance: Torlon exhibits excellent tribological properties, including low friction and wear resistance. This makes it suitable for applications that involve sliding or rotating components, such as bearings, bushings, and wear pads.
  6. Electrical Insulation: Torlon is an excellent electrical insulator, offering high dielectric strength and low electrical conductivity. It is often used in electrical and electronic components where insulation and electrical performance are critical.
  7. Machinability: Torlon is known for its machinability, allowing it to produce complex shapes and precise components. It can be easily machined using conventional machining techniques, including milling, turning, drilling, and grinding.

Due to its exceptional properties, Torlon is commonly found in industries such as aerospace, automotive, electronics, oil and gas, chemical processing, and various other high-performance applications that demand precision, reliability, and durability.

For more information on Torlon or how a high-performance polymers can benefit your application, please contact Rich Reed, Vice President of Sales and Marketing at [email protected] or visit our website at www.performanceplastics.com.

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