Our Polyether Ether Ketone PEEK Injection Molding Services

Elevate high-performance component manufacturing with our PEEK Injection Molding services—where the exceptional strength of Polyetherether Keton (eine oberste Stufe Hochleistungs-Thermoplastik) erfüllt Precision Engineering. From medical implants to aerospace brackets, we deliver parts that thrive in extreme temperatures, harte Chemikalien, and critical applications, backed by strict compliance with ISO 10993 Und ASTM D638 Standards.

Holen Sie sich kostenloses Zitat

Definition: Understanding PEEK Injection Molding

PEEK Injection Molding is the process of shaping Polyetherether Keton (SPÄHEN)—a semicrystalline, high-performance thermoplastic—into custom components via injection molding. PEEK stands out as a semicrystalline polymer with unparalleled thermal, mechanisch, und chemischer Widerstand, making it the material of choice for industries where failure is not an option. Below is a breakdown of key definitions, Spezifikationen, and comparisons to similar polymers:​

Core Specifications & Standards​

​

​

PEEK vs. Similar High-Performance Polymers​

​

​

Zusamenfassend, PEEK Injection Molding leverages the polymer’s balanced properties—strength, Wärmewiderstand, and biocompatibility—to solve challenges that conventional plastics (and even metals) cannot address. Unser service scope covers everything from material selection (pro PEEK grade specs) to final part validation.

Unsere Fähigkeiten: Mastering High-Performance PEEK Molding

Bei Yigu Technology, unser PEEK Injection Molding capabilities are engineered to unlock the full potential of this advanced material. We invest in specialized equipment and expertise to handle PEEK’s unique processing requirements (Hohe Temperatur, genaue Kontrolle). Below is a detailed overview of our core capabilities:​

Key Capabilities & Anwendungen

​

​

Unser rapid tooling change Fähigkeit (unter 4 Std.) also ensures flexibility—whether you need small-batch prototypes or large-volume production runs, we adapt quickly without sacrificing quality.

Verfahren: Step-by-Step PEEK Injection Molding

PEEK’s unique properties require a highly controlled injection molding process—even minor deviations in temperature or pressure can compromise part quality. Below is our optimized PEEK molding cycle, designed to maximize consistency and performance:​

Schritt 1: Materialvorbereitung (Trocknen)​

PEEK is hygroscopic (absorbiert Feuchtigkeit), which causes bubbling and voids in finished parts. We dry PEEK pellets in a dehumidifying dryer at 150 ° C für 4 Std. (critical for maintaining material integrity). For medical-grade PEEK, we use nitrogen-purged dryers to prevent contamination.​

Schritt 2: Schimmeldesign & Preparation​

• Gate & Runner Design: We use hot runners (instead of cold runners) to minimize PEEK waste (hot runners keep material molten, reducing scrap by 25–30%). Gates are placed to avoid shear stress (PEEK is sensitive to excessive shear, which degrades its strength).​

• Schimmelpilzregelung: Molds are heated to 150–200 ° C. (via oil or electric heaters) to promote uniform crystallization—this ensures Dimensionsstabilität and prevents warping. Für dicke Teile, we use gradient heating (warmer at the core, cooler at the surface).​

Schritt 3: Injection Molding Machine Setup​

• High-Heat Barrel Settings: Barrel zones are set to a temperature gradient (Futterzone: 360 ° C; melt zone: 380–400 ° C.; Düse: 390–410 °C) to melt PEEK without thermal degradation.​

• Inert-Gas Venting: We purge the mold cavity with nitrogen during injection to remove air (PEEK’s high viscosity traps air easily, leading to defects). This step is mandatory for parts like semiconductor clamps (where even tiny voids cause failure).​

Schritt 4: Injektion & Packing​

• Einspritzgeschwindigkeit: Slow to moderate (50–100 mm/s) to control shear (excessive shear reduces PEEK’s tensile strength by 10–15%).​

• Packing Pressure: 80–90% of injection pressure, held for 10–20 seconds to compensate for shrinkage (PEEK shrinks 1.5–2.5% during cooling).​

Schritt 5: Kühlung & Demolding

Die Kühlzeit variiert je nach Teildicke (10 seconds for thin parts, 60 seconds for thick sections). We use controlled cooling to maintain crystallinity (Ziel: 35–40% for most applications; higher for structural parts, lower for flexible components). Demolding is done with gentle ejectors to avoid scratching (kritisch für medizinische Implantate).​

Schritt 6: Nachbearbeitung & Qualitätskontrolle

• Glühen: Parts are heated to 180–200 °C for 1–2 hours, dann langsam abgekühlt (5 ° C/min) to relieve internal stresses. This step improves dimensional stability by 20–25%.​

• SPC Monitoring: We use Statistical Process Control (SPC) to track key parameters (Temperatur, Druck, Zykluszeit) in Echtzeit. Any deviation beyond ±2% triggers an alert, Gewährleistung einer konsequenten Qualität.

Inspektion: Parts undergo dimensional testing (CMM), mechanical testing (tensile strength per ASTM D638), und visuelle Inspektion (for defects like flash or voids).

Materialien: Choosing the Right PEEK Grade for Your Project

PEEK is available in various grades, each formulated to enhance specific properties (Stärke, Resistenz tragen, Biokompatibilität). The right grade depends on your application’s unique demands. Below is a guide to the most common PEEK grades we use:​

Popular PEEK Grades & Their Uses​

​

​

Grade Selection Checklist​

1. Temperature Requirement: If parts face >240 °C (Z.B., Motorkomponenten), choose glass/carbon-filled grades (they retain strength at high heat).​

2. Biokompatibilität: Für medizinischen Gebrauch, wählen Implantable PEEK-OPTIMA (trifft ISO 10993) or FDA food-contact grades (Z.B., Vestakeep MED).​

3. Resistenz tragen: Für bewegliche Teile (Z.B., Lager), pick carbon-filled or bearing-grade PEEK (Z.B., Ketaspire KT-220).​

4. Flame Safety: Für Elektronik, ensure the grade meets Ul 94 V-0 (all standard PEEK grades qualify).​

We maintain global supply contracts with Victrex, Solvay, and Evonik, ensuring consistent access to high-quality PEEK—even for high-volume orders.

Oberflächenbehandlung: Verbesserung der Performance von Peek -Teil

PEEK’s inherent properties are exceptional, Aber Oberflächenbehandlung can further expand its capabilities—whether you need better adhesion, Biokompatibilität, oder Widerstand tragen. Below are the most effective surface treatments for PEEK parts:​

​

​

Zum Beispiel, Wir verwenden Ti-coating PEEK for dental implants to make them visible on X-rays (PEEK is radiolucent) and improve long-term stability in the jawbone. For semiconductor parts, Polieren (Ra <0.1 µm) ensures no particle buildup on critical surfaces.

Vorteile: Why PEEK Injection Molding Outperforms Alternatives

PEEK Injection Molding offers a unique set of advantages that make it irreplaceable in critical applications. Compared to metals (Stahl, Aluminium) and other plastics (Pa, Pps), PEEK delivers unmatched value:​

Key Advantages of PEEK​

• Extreme Temperature Resistance: PEEK maintains 90% of its strength at 240 ° C (kontinuierlicher Gebrauch) and can withstand short-term exposure to 300 ° C. This outperforms aluminum (loses strength at 200 ° C) und pps (continuous use limit: 200 ° C).​

• Chemical Inertness: Öle resistent, Lösungsmittel, Säuren, und Basen (even concentrated sulfuric acid at room temperature). Im Gegensatz zu Metallen, it won’t corrode—ideal for oil & gas and chemical processing parts.​

• Steam & Radiation Sterilizable: Can undergo 1,000+ Autoklavenzyklen (134 ° C, 3 Bar) and is resistant to gamma radiation (25 kGy). This makes it the top choice for reusable medical instruments.​

• Superior Strength-to-Weight Ratio: PEEK has a density of 1.32 g/cm³ (50% leichter als Stahl) but tensile strength comparable to aluminum. Für Luft- und Raumfahrtteile, this reduces fuel consumption by 5–10%.​

• Resistenz tragen: Carbon-filled PEEK has a wear rate 10x lower than nylon and 2x lower than bronze—perfect for bearings and sliding components that operate without lubrication.​

• Low Outgassing: Emits minimal volatile organic compounds (VOCs) beim Erhitzen. This meets NASA’s outgassing standards (ASTM E595), making it suitable for space applications.​

• Biokompatibilität (USP Class VI): Implantable PEEK-OPTIMA is compatible with human tissue, causing no immune response. It’s used in spinal cages, Hüftbecher, and dental implants.​

• Dimensionsstabilität: Niedriger Koeffizient der thermischen Expansion (CTE: 3.1–5.5 × 10⁻⁵/°C) and minimal shrinkage (1.5–2,5%) ensure parts retain their shape in temperature fluctuations.​

Metal Replacement: PEEK parts cost 20–30% more upfront than metal but last 3–5x longer (Keine Korrosion, Weniger Verschleiß). Zum Beispiel, a PEEK turbine bushing replaces a steel one, Die Wartungskosten durch senken 60%.

Anwendungsbranche: Where PEEK Injection Molding Shines

PEEK Injection Molding serves industries that demand reliability in extreme conditions. Below’s how key sectors leverage PEEK’s properties to solve their toughest challenges:​

​

​Aerospace is a standout example: PEEK engine brackets replace aluminum, cutting part weight by 40% and improving fuel efficiency—critical for airlines aiming to reduce carbon emissions. In medical, PEEK spinal cages integrate with bone tissue better than metal (no “stress shielding” that weakens surrounding bone), leading to faster patient recovery.​

Fallstudien: Real-World Success with PEEK Injection Molding

Unser PEEK Injection Molding services have solved complex challenges for clients across high-stakes industries. Below are detailed case studies highlighting measurable results—from weight savings to accelerated time-to-market:​

Fallstudie 1: PEEK Turbine Bushing for Oil & Gas (60% Gewichtsreduzierung)​

• Herausforderung: A global oilfield services company needed to replace steel turbine bushings in down-hole pumps. The steel parts were heavy (Hinzufügen 15 lbs to each pump), corroded in saltwater (failing after 6 Monate), and required frequent lubrication—driving high maintenance costs.​

• Lösung: Wir haben empfohlen mit Kohlenstoff gefüllter Blick (Solvay Ketaspire KT-820 CF30) for its wear resistance, chemische Trägheit, und leichte Eigenschaften. Unser thick-section molding capability handled the bushing’s 20mm thickness, während inert-gas venting eliminated voids (critical for withstanding down-hole pressure of 20 ksi). We also added a PVD tungsten carbide coating to boost wear resistance.​

• Ergebnis: The PEEK bushings weighed 60% Weniger als Stahl (3 lbs vs. 7.5 lbs per unit), reducing pump total weight by 12 Pfund. They resisted saltwater corrosion and operated without lubrication, Verlängerung der Lebensdauer auf 3 Jahre (6x longer than steel). Die Wartungskosten wurden um gesunken $250,000 annually per rig, delivering a 3:1 ROI In 8 Monate.

• Kundenaussage: “The PEEK bushings transformed our pump reliability. We’ve cut maintenance visits by 80%—a game-changer for remote offshore rigs.” — Oilfield Operations Director​

Fallstudie 2: Spinal Implant for Medical Device Maker (30-Day Launch)​

• Herausforderung: A medical device startup needed a spinal fusion cage for orthopedic trials. Das erforderliche Teil implantable PEEK-OPTIMA (USP Class VI compliant), enge Toleranzen (± 0,01 mm) for bone fit, and a porous surface for tissue integration. The startup had a strict 30-day timeline to meet FDA trial deadlines—far faster than the industry’s typical 8–10 week lead time for medical PEEK parts.​

• Lösung: We leveraged our 24-hour prototyping capability to create a 3D-printed PEEK prototype in 48 hours for fit testing. Für die Produktion, we used our clean-room ISO 7 facility to avoid contamination, Und chromic acid etching to create the porous surface (enhancing bone integration). Unser lot traceability (FDA/UDI) system tracked every step—from PEEK-OPTIMA raw material batch to finished implant.​

• Ergebnis: Wir haben geliefert 50 implantable cages in 28 Tage (2 Tage vor dem Zeitplan), meeting the startup’s trial deadline. The cages passed all biocompatibility tests (ISO 10993) and achieved 90% tissue integration in pre-clinical trials. The startup later scaled production to 500 units/month using our multi-cavity tools, cutting per-unit cost by 35%.​

• ROI Analysis: The accelerated launch let the startup begin clinical trials 3 Monate früher, positioning them as a first-mover in the spinal implant market—projected to generate $2M in additional revenue in the first year.​

Fallstudie 3: High-Speed PEEK Gear for Automotive (15,000 RPM Durability)​

• Herausforderung: Ein luxuriöses Elektrofahrzeug (Ev) manufacturer needed a transmission gear that could withstand 15,000 Drehzahl (higher than traditional gas engines) without overheating or wearing out. Metal gears were too noisy and added weight (hurting EV range), while standard plastics (PA66) melted at the gear’s operating temperature (180 ° C).​

• Lösung: Wir haben ausgewählt bearing-grade PEEK (Solvay Ketaspire KT-220) for its low friction coefficient (0.2) und thermische Stabilität (continuous use at 240 ° C). Unser mold-flow analysis optimized the gear’s tooth geometry to reduce shear stress during molding, während annealing post-process relieved internal stresses (preventing warping at high RPM). Wir haben auch benutzt laser texturing on gear teeth to improve lubricant retention.​

• Ergebnis: The PEEK gear operated smoothly at 15,000 Drehzahl für 1,000+ Std. (Äquivalent zu 100,000+ miles of driving) with no wear. It weighed 45% Weniger als Metall, extending the EV’s range by 8 miles per charge, und reduzierte Übertragungsgeräusche durch 12 db (a key luxury feature). The manufacturer scaled to 10,000 gears/month using our multi-cavity tools, mit a 99.9% defect rate.​

Fallstudie 4: Electronic Housing for Semiconductor (260 °C Solder Bath Resistance)​

• Herausforderung: A semiconductor equipment maker needed a housing for wafer-handling robots that could survive 260 °C solder bath exposure (during maintenance) and had ultra-low outgassing (to avoid contaminating wafers). Metal housings were too heavy and conducted heat (risking wafer damage), while PPS housings warped at 220 °C.​

• Lösung: Wir haben benutzt general-purpose PEEK (Victrex 450G) for its thermal resistance and low outgassing (meets ASTM E595). Unser Polieren (Ra <0.1 µm) process created a mirror-smooth surface that prevented particle buildup, Und in-house mold-flow analysis designed the housing with thin, uniform walls (avoiding hot spots during molding). Wir haben auch a hinzugefügt UV-resistente Beschichtung to protect against cleanroom lighting.​

Ergebnis: The PEEK housing survived 50+ solder bath cycles (260 ° C für 10 Minuten) without warping or discoloration. Its low outgassing kept wafer defect rates below 0.01%—a critical requirement for advanced chip manufacturing. The client replaced all metal housings with PEEK, cutting robot weight by 30% and improving maneuverability.

Warum uns wählen?: Your Trusted PEEK Injection Molding Partner

PEEK Injection Molding demands specialized expertise—even small mistakes (Z.B., insufficient drying, incorrect mold temperature) can ruin expensive PEEK material and delay critical projects. Here’s why clients in aerospace, medizinisch, and industrial sectors choose our services:​

1. Industry-Leading Certifications & Compliance​

Wir halten AS9100 (Luft- und Raumfahrt) Und ISO 13485 (medizinisch) certifications—rigorous standards that ensure consistency and compliance for high-stakes applications. Our cleanrooms (ISO 7) meet FDA requirements for medical implant production, und unser lot traceability (FDA/UDI) system satisfies aerospace and medical documentation needs. We also comply with ASTM D638 (mechanical testing) und ISO 10993 (Biokompatibilität), so you never have to worry about regulatory gaps.​

2. Specialized Expertise & Equipment​

• 50+ PEEK Molds/Year: We design and build 50+ custom PEEK molds annually—more than most competitors—giving us deep experience in optimizing mold geometry for PEEK’s high viscosity and crystallization needs.​

• 400 °C+ Machines: Our fleet of 15 injection molding machines is specially modified to reach 400 ° C+ (critical for melting PEEK) and maintain ±1 °C temperature precision—avoiding thermal degradation.​

• In-House Rheology Lab: We test PEEK melt flow (Mfr) and viscosity before every production run, ensuring material consistency. This lab also lets us customize PEEK formulations (Z.B., adding glass fibers for strength) for unique client needs.​

3. Geschwindigkeit & Flexibilität

• 24-Hour Prototyping: We use high-temperature 3D printing (Peek -Filament) to deliver functional prototypes in 24–48 hours—accelerating design validation and reducing time-to-market by 4–6 weeks.​

• Rapid Tooling Change: Our tooling team can switch molds in under 4 Std. (vs. 8–12 hours for competitors), making us ideal for clients with multiple part SKUs or small-batch runs.​

• PPAP Level 3 Unterstützung: Für Automobilkunden, we provide Production Part Approval Process (PPAP) Ebene 3 documentation—including dimensional reports, Materialzertifikate, and process capability studies (Cpk ≥ 1.33).​

4. Global Supply Chain & Nachhaltigkeit

• Global PEEK Supply Contracts: We have long-term contracts with Victrex, Solvay, and Evonik—ensuring access to high-quality PEEK (even during material shortages) and consistent pricing for high-volume orders.​

• Energy-Efficient Presses: Our molding machines use variable-frequency drives (VFDs) and heat-recovery systems, cutting energy consumption by 25% vs. standard machines. This reduces our carbon footprint and lowers costs for clients.​

• Abfallreduzierung: We reuse PEEK scrap (via regranulation) für nicht kritische Teile (Z.B., Prototypen), keeping material waste below 5%—far better than the industry average of 10–15%.​

5. Long-Term Support & IP Protection​

• Lifetime Tool Maintenance: We offer free annual maintenance for PEEK molds (Reinigung, wear part replacement) to extend tool life to 500,000+ Zyklen (vs. 300,000 cycles without maintenance).​

• IP Protection Program: We sign non-disclosure agreements (Der) for all custom projects and restrict access to client designs to authorized team members only—critical for startups and companies with proprietary technology.​

24/7 Technische Unterstützung: Our PEEK engineers are available 24/7 to troubleshoot issues (Z.B., part warping, dimensional 偏差) and adjust processes—minimizing production downtime.

FAQ