Injection Molding or Machining Molding… How you do it is up to you.

Because of its versatility, it is important to discuss PEEK’s injection molding and machining molding operations. To be clear, neither method is universally superior. Project engineers should consult with component manufacturers about the process selection they end up using.

When injection molding PEEK, a complicated tool, often costing more than $10,000, is used to create a unique cavity for the material.  If the cost of the necessary tools is reasonable, this is the best and quickest method for producing the component. However, in machining, standard metal part production methods are mimicked through the use of stock forms and machine shops.  In most cases, bushings and bearings may be machined from a single bar of PEEK rod for hundreds of dollars and in as little as a few days.  Extruded shapes provide the highest stiffness, greatest toughness, and most reliable performance because of their qualities.

In most cases requiring a high degree of accuracy, machining PEEK is the method of choice. This is the case, for example, when toughness and impact strength are highly valued yet production volumes are limited (particularly for runs of fewer than 5,000 parts) and when larger components must be manufactured. When high mechanical and wear attributes are essential, machining is the way to go.

Read more: What Is Injection Molding?

Again, neither method is inherently superior to the other, although one does have significant benefits under certain conditions. When mass-producing complex parts (often over 10,000 in a single run), injection moulding PEEK is the best option because of the elimination of machining time and waste, resulting in the lowest potential unit costs. When complicated geometric issues arise during machining, injection molding is the best option.

Where Can I Find PEEK?

Most PEEK sold around the world is in its unfilled form.  PEEK is the material of choice where high strength and inertness are required, especially at elevated temperatures, due to its durability, availability, and processability. The polymer continues to find innovative applications. The polymer has many important applications, including:

• PEEK is ideally suited for use in the fabrication of semiconductors and electronics because it maintains its strength and purity even when exposed to high temperatures and severe chemicals. Wafer handling tools and hardware made from PEEK can be manufactured for use in processes like chemical cleaning. During chemical mechanical planarization and etching, for example, unfilled PEEK is essential. The mobile phone industry is one of the main consumers of PEEK films.

• Seals and electrical connectors made from unfilled PEEK and glass-filled PEEK are commonly used in the oil and gas industry as insulators, isolators, and reinforcements for softer seal materials. PEEK is an excellent material for use in the oil and gas industry because it is resistant to the steam and chemicals found in harsh downhole conditions. Downstream PEEK valve seats and seals help regulate the chemically stable flow of petrochemical gases and liquids.

• In the aerospace industry, PEEK is used in both civilian and military aircraft because of its reliability and durability. Unfilled PEEK is so resistant to heat and fire that it self-extinguishes, making it a useful material in the aircraft industry because of its low smoke generation and good thermal resistance. These characteristics make it an excellent choice for use in thermal isolators, which must withstand extreme temperatures, as well as in the highly stressed electronics used in aircraft applications. Carbon fiber-reinforced PEEK grades, such as 450CA30 and KT820CF30, offer superior strength and stiffness to glass fiber-reinforced PEEK grades without the latter’s excessive density.

• In the medical field, unfilled PEEK is used as spinal and dental implants due to its biocompatibility, which has already been addressed. Implants made from carbon fiber-reinforced PEEK are so long-lasting that they often outlast their patients. Because of its inertness and stability, PEEK can be used in reusable medical equipment that is subjected to autoclaving. PEEK’s radiolucency is a nice bonus. That is to say, X-rays, CT scans, and MRI scans can’t detect PEEK, and the same is true for magnetic resonance imaging (MRI). Because the implant will not block the view of the tissues around it, radiolucency is particularly useful for examining tissue growth processes.

• Unfilled PEEK is available in food-grade variations, making it suitable for use in food-contact appliances and surfaces. Filling nozzles, mixing paddles, bearings, bushings, and valve components are commonplace uses, particularly in machines that fill hot liquids, such as those used to process citrus fruits. Due to rising process temperatures, unfilled polyetheretherketone (PEEK) has replaced acetal in valve bodies. In addition, clean-in-place (CIP) treatments have no effect on unfilled PEEK.

How many distinct PEEK materials are there?

• Chemically inert, FDA-compliant, and heat-resistant to 300 degrees Fahrenheit, unfilled PEEK is hard to beat. Tolerance-critical, complicated machined parts or injection-moulded parts, like gears, ferrules, and life-science and medical components, benefit greatly from this polymer’s better machinability and cleanliness compared to other ketone-based polymers. To learn more, visit KT820NT in Depth.

• PEEK grades with carbon fibre reinforcement are the strongest and stiffest available.  Despite having higher reinforcement per volume, it is 7 percent lighter than glass-reinforced grades. It works wonderfully for heavy-duty machined or molded components. For a more in-depth look, research 450CA30 or KT820CF30.

• Glass-fiber-reinforced PEEK has superior mechanical properties to those of unfilled PEEK grades, as well as superior electrical and thermal insulation. It’s a great material for electrical connector bodies and other heavy-duty machined or moulded components, like backup seals. Read this extensive analysis of the KT820GF30 here!

• Value of Bearings When it comes to PEEK grades, the ones best suited for high-wear situations are those with the lowest wear rates.  Graphite, polytetrafluoroethylene (PTFE), and carbon fiber, typically in a 10-10-10 ratio, are found in the most popular grades. This synergy between reduced friction and strong conductivity leads to increased PVs and decreased wear rates. For Detailed Accounts, Examine Either the 450FC30 or KT820SL30, or the 450FE20, Both, or neither.

• High-temperature PEEK or PEK is based on polyether ketone PEK rather than PEEK and hence has a slightly different chemical composition. Both PEK and PEKEKK have higher softening temperatures compared to standard PEEK.  PEEK’s potential in downhole electrical connectors is increased by this development because PEK-based materials like HT can now maintain strength and stiffness at 50°F higher temperatures.