Our Polyether Imide PEI Injection Molding Services

Elevate high-performance component manufacturing with our PEI Injection Molding services—where the exceptional thermal stability of Политимид (высший уровень amorphous high-performance thermoplastic) соответствует точной инженерии. From flame-retardant aircraft parts to sterilizable medical tools, we deliver parts that thrive in extreme heat and critical applications, backed by strict compliance with ASTM D5205 и Rohs/Reach стандарты.

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Определение: Understanding PEI Injection Molding

PEI Injection Molding is the process of shaping Политимид (Пей)—a high-performance amorphous thermoplastic—into custom components via injection molding. Пей (commercially known as Ultem molding) stands out for its unique combination of thermal resistance, пламенная задержка, и прозрачность, making it ideal for industries where safety, долговечность, and precision are non-negotiable. Below is a breakdown of key definitions, спецификации, и основные свойства:​

Core Specifications & Standards​

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Ключевая черта: Amorphous vs. Semicrystalline Polymers​

Unlike semicrystalline polymers (НАПРИМЕР., Заглядывать), PEI is аморфный—it lacks a defined crystalline structure, which gives it unique advantages:​

• Better dimensional stability (no shrinkage from crystallization)​

• Uniform transparency (no light scattering from crystals)​

• Easier processing for thin-wall parts (consistent melt flow)​

Это делает PEI Injection Molding the top choice for parts requiring precision and clarity, such as optical sensors and medical instrument trays.

Наши возможности: Mastering High-Performance PEI Molding

В Yigu Technology, наш PEI Injection Molding capabilities are engineered to unlock the full potential of this advanced material. We invest in specialized equipment and expertise to handle PEI’s unique processing requirements (высокая температура, low-shear needs). Below is a detailed overview of our core capabilities:​

Key Capabilities & Приложения

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Наш 48-hour T1 sampling capability also ensures fast validation of mold designs—critical for accelerating new product launches.

Процесс: Step-by-Step PEI Injection Molding

PEI’s amorphous structure and high melt temperature require a highly controlled injection molding process—even minor deviations can compromise transparency, сила, or dimensional accuracy. Below is our optimized process, designed to maximize consistency and performance:​

Шаг 1: Материал подготовка (Сушка)​

PEI is hygroscopic (Поглощает влагу), which causes bubbles and surface defects. We dry PEI pellets in a dehumidifying dryer at 150 ° C для 4 часы (target moisture content: <0.02%). For medical-grade PEI (НАПРИМЕР., Ultem HU), we use nitrogen-purged dryers to prevent contamination.​

Шаг 2: Дизайн плесени & Preparation​

• Hot-Runner Manifold: We use hot runners (instead of cold runners) to keep PEI molten, reducing scrap by 30–35% and ensuring uniform flow into the mold.​

• Контроль температуры формы: Molds are heated to 140–180 °C (via oil heaters) to prevent premature cooling (which causes flow marks in amorphous materials). Для тонкостенных деталей (0.2 мм), we use gradient heating to maintain consistent mold temp across cavities.​

Шаг 3: Настройка машины

• High-Heat Barrel Profile: Barrel zones are set to a precise gradient:​

• Feed zone: 340 ° C. (melts pellets without degradation)​

• Melt zone: 360–370 ° C. (maintains optimal viscosity)​

• Nozzle: 370–380 °C (prevents material solidification)​

• Low-Shear Screw Design: Our screws have deep flights and slow rotation (50–70 RPM) to minimize shear stress—excessive shear breaks PEI’s polymer chains, reducing strength by 15–20%.​

Шаг 4: Инъекция & Packing​

• Injection Speed: Умеренный (80–100 мм/с) to fill cavities without creating air pockets. Для тонкостенных деталей, we use fast injection (120–150 mm/s) to avoid short shots.​

• Packing Pressure: 85–90% of injection pressure, held for 15–20 seconds to compensate for amorphous shrinkage (PEI shrinks 0.5–0.8% during cooling).​

• Nitrogen Assist: Для сложных частей (НАПРИМЕР., with undercuts), we inject nitrogen into the mold to push PEI into hard-to-reach areas—reducing defects by 40%.​

Шаг 5: Охлаждение & Демольд

Время охлаждения варьируется в зависимости от толщины части (10 seconds for 0.2 ММ детали, 60 seconds for 5 ММ детали). We use controlled cooling to avoid internal stresses—critical for maintaining dimensional stability. Demolding is done with soft ejectors to prevent scratching (especially important for optical-grade molding).​

Шаг 6: Пост-обработка & Контроль качества

• Annealing Stress Relief: Parts are heated to 160–180 °C for 1–2 hours, затем медленно охлаждался (5 ° C/мин) to relieve internal stresses. This step improves dimensional stability by 25–30%.​

• Automated Degating: Robots remove runners/gates, ensuring consistent part quality and faster production.​

Осмотр: Parts undergo CT scanning (Для внутренних дефектов), Размерное тестирование (ШМ), and transparency testing (ASTM D1003). Для медицинских деталей, we add biocompatibility testing (Iso 10993).

Материалы: Выбор правильной оценки PEI для вашего проекта

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

Popular PEI Grades & Their Uses​

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Grade Selection Checklist​

1. Temperature Requirement: If parts face >200 °C (НАПРИМЕР., EV batteries), choose glass/carbon-reinforced grades (НАПРИМЕР., Ультом 2300).​

2. Прозрачность: Для оптических частей (НАПРИМЕР., датчики), pick Sabic Ultem 1000 (transparent amber).​

3. Medical/Food Use: Выбирать Ультом 1010 (FDA grade) или Medical Ultem HU (биосовместимый).​

4. Anti-Static Needs: Choose ESD PEI for electronic components.​

Мы поддерживаем global Sabic distributor pact, ensuring consistent access to high-quality PEI—even for high-volume orders.

Поверхностная обработка: Enhancing PEI Part Performance

PEI’s inherent properties are exceptional, но Поверхностная обработка can further expand its capabilities—whether you need better conductivity, Сопротивление царапин, or bonding. Below are the most effective surface treatments for PEI parts:​

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Например, Мы используем PVD sputtering on optical sensor housings to protect against scratches, и laser marking amber on medical trays to ensure traceability through repeated sterilization.

Преимущества: Why PEI Injection Molding Outperforms Alternatives

PEI Injection Molding offers a unique set of advantages that make it irreplaceable in critical applications. Compared to metals (алюминий, сталь) and other plastics (А, Заглядывать), PEI delivers unmatched value:​

Key Advantages of PEI​

• Extreme Thermal Resistance: PEI maintains 90% of its strength at 217 ° C. (непрерывное использование) and can withstand short-term exposure to 300 ° C.. This outperforms PA66 (continuous use limit: 150 ° C.) and matches PEEK—at a lower cost.​

• Inherent Flame Retardancy: UL 94 V.-0 inherent (no additives needed) means PEI won’t catch fire or release toxic smoke—critical for aircraft, Электроника, и медицинские учреждения. It also meets NASA’s low-smoke requirements (ASTM E662).​

• Transparent High-Heat: Transparent amber grade PEI transmits 90–94% of light (for thin parts) пока выдерживался 217 °C—something no other transparent plastic (НАПРИМЕР., ПК, акрил) can do. Ideal for high-heat optical components.​

• Совместимость стерилизации: PEI withstands 1,000+ Циклы автоклав (134 ° C., 3 бар), Гамма -радиация (25 kGy), and ethylene oxide (ETO) sterilization—perfect for reusable medical tools.​

• Low Smoke Toxicity: When exposed to fire, PEI releases minimal toxic gases (НАПРИМЕР., cyanide, хлор) compared to halogenated plastics. This makes it the top choice for enclosed spaces (aircraft cabins, больницы).​

• High Dielectric Strength: PEI has a dielectric strength of 21 kV/mm—excellent for electrical insulation (НАПРИМЕР., EV battery insulators, 5G antenna filters). It also maintains insulation properties at high temperatures.​

• Размерная стабильность: As an amorphous polymer, PEI has low shrinkage (0.5–0,8%) and a low coefficient of thermal expansion (CTE: 5.5 × 10⁻⁵/°C). This ensures parts retain their shape in temperature fluctuations.​

• Химическая устойчивость: Resistant to hydrocarbons (масла, топливо), weak acids, and alcohols. It’s also resistant to most cleaning agents—ideal for medical and food-service parts.​

Metal Replacement Weight-Out: PEI is 50–60% lighter than aluminum and 70–80% lighter than steel. For aircraft parts, this cuts fuel consumption by 5–10%; для электромобилей, it extends range by 3–5%. Например, replacing aluminum aircraft seat clips with PEI cuts each clip’s weight by 30%, reducing total aircraft weight by 150 lbs and saving airlines $20,000+ in fuel annually per plane.

Индустрия приложений: Where PEI Injection Molding Delivers Value

PEI Injection Molding serves industries that demand a rare mix of thermal resistance, безопасность, и точность. From aerospace cabins to medical operating rooms, PEI solves unique challenges that other materials can’t. Below’s how key sectors leverage PEI’s properties:​

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A standout example is in medical autoclave cassettes: PEI’s ability to withstand 1,000+ Циклы стерилизации (против. 200 cycles for polycarbonate) means hospitals replace cassettes 5x less often—cutting costs and waste. In EVs, PEI battery insulators prevent short circuits while enduring the heat of fast charging, a job no standard plastic can handle.

Тематические исследования: Real-World Success with PEI Injection Molding

Наш PEI Injection Molding services have helped clients across high-stakes industries solve complex problems—from cutting aerospace fuel costs to accelerating medical device launches. Below are detailed case studies with measurable results:​

Тематическое исследование 1: Aerospace Seat Clip (30% Снижение веса, Fire Safety Compliance)​

• Испытание: A major airline needed to replace aluminum seat back clips to reduce aircraft weight (for fuel savings) while meeting strict FAA fire safety standards (UL 94 V.-0, low smoke toxicity). Aluminum clips were heavy (20г каждый) and failed the smoke test; standard plastics (ПА66) melted at 180 ° C. (too low for cabin heat).​

• Решение: Мы рекомендовали Aerospace Ultem 9085—a grade engineered for aircraft interiors. Наш tight-tolerance ±0.01 mm molding ensured the clips fit existing seat hardware, и automated degating kept production costs low for high volume (100,000 clips/year). We also performed fire testing to validate UL 94 V.-0 соответствие.

• Результат: The PEI clips weighed just 14g (30% легче алюминия), reducing total aircraft weight by 150 фунт. They passed FAA fire tests with flying colors (low smoke, no flame spread) and lasted 2x longer than aluminum (resisting corrosion from cabin humidity). The airline saved $22,000 in fuel per plane annually, с ROI of 18 месяцы.​

• Отзывы клиента: “The PEI clips solved two problems at once—weight and fire safety. We’re now rolling them out across our entire fleet.” — Aerospace Interior Engineering Manager​

Тематическое исследование 2: Reusable Medical Autoclave Tray (3,000 Sterilization Cycles)​

• Испытание: A medical device company needed a reusable tray for surgical instruments that could withstand Циклы автоклав (134 ° C., 3 бар) without warping or yellowing. Their current polycarbonate trays failed after 200 цикл, forcing hospitals to replace them monthly—creating waste and high costs.​

• Решение: Мы использовали Medical Ultem HU (биосовместимый, USP Class VI) for the tray material. Наш clean-room ISO 8 production prevented contamination, и annealing stress relief ensured dimensional stability (trays retained their shape even after repeated heating). We added laser marking amber for permanent lot numbers (critical for traceability).​

• Результат: The PEI trays survived 3,000 Циклы автоклав (15x longer than polycarbonate) and showed no yellowing or warping. Hospitals reduced tray replacement costs by 93% (from ​500/монеТчасТо35/месяц) and cut plastic waste by 2,800 trays per year. The device company won a $2M contract with a large hospital network due to the tray’s durability.​

• ROI Analysis: For a hospital using 50 лотки, the switch to PEI saved $27,900 ежегодно. For the device company, the product’s unique selling point (3,000 цикл) increased market share by 12%.​

Тематическое исследование 3: EV Battery Bushing Insulator (150 °C Continuous Operation)​

• Испытание: An electric vehicle manufacturer needed an insulator for battery bus-bars that could handle 150 ° C. (the temperature of fast-charging batteries) while insulating 800V electrical current. Rubber insulators melted at 120 ° C.; ceramic insulators were brittle and heavy (добавление 5 lbs to the battery pack).​

• Решение: Мы выбрали glass-filled Ultem 2300 for its high dielectric strength (21 kV/mm) и 217 ° C Непрерывное использование температура. Наш in-house mold-flow analysis optimized the insulator’s design to fit tight battery pack spaces, и insert molding circuits let us integrate metal contacts directly into the PEI (eliminating secondary assembly).​

• Результат: The PEI insulator operated flawlessly at 150 ° C для 1,000+ часы (эквивалентно 100,000+ miles of driving) and maintained its insulation properties. It weighed 70% less than ceramic (0.3 lbs vs. 1 lb per insulator), cutting battery pack weight by 4 lbs and extending EV range by 3 мили. The manufacturer scaled to 50,000 insulators/month using our multi-cavity tools, с 99.9% defect rate.​

Тематическое исследование 4: Surgical Drill Guide (50 μm Tolerance for Precision Surgery)​

• Испытание: A dental implant company needed a drill guide that could align drills within 50 мкм (0.05 мм) of the target (critical for accurate implant placement). The guide also needed to be sterilizable (Гамма -радиация) and visible under X-rays (for surgeons to verify alignment). Standard plastic guides had tolerances of 200 мкм (too loose) and were radiolucent (невидимый на рентгеновских снимках).​

• Решение: Мы использовали Medical Ultem HU for biocompatibility and added barium sulfate (a radiopaque additive) to make the guide visible on X-rays. Наш tight-tolerance ±0.01 mm molding (with Cpk ≥ 1.67) гарантировал 50 μm precision, и diamond polish created a smooth inner surface (preventing drill slippage). We validated the guide with 100+ surgical tests.​

Результат: The PEI drill guide reduced implant placement error by 75% (от 200 мкм до 50 мкм), improving patient outcomes (fewer revision surgeries). It withstood 500+ gamma radiation cycles without degradation, and surgeons praised its X-ray visibility. The company’s implant success rate rose from 92% к 98%, Увеличение продаж 15%.

Почему выбирают нас: Your Trusted PEI Injection Molding Partner

PEI Injection Molding requires specialized expertise—PEI’s high melt temperature and amorphous structure leave little room for error. Here’s why clients in aerospace, медицинский, and EV industries choose our services:​

1. Industry-Leading Certifications & Compliance​

Мы держим AS9100 (аэрокосмическая) и Iso 13485 (медицинский) certifications—two of the most rigorous standards for high-stakes manufacturing. Наш clean-room ISO 8 facility meets FDA cGMP requirements for medical device production, and all our PEI parts comply with Rohs/Reach (Нет опасных веществ) и ASTM D5205 (PEI material specifications). Для автомобильных клиентов, Мы предоставляем PPAP Level 4 поддерживать—including detailed process capability studies and material traceability—to meet IATF 16949 стандарты.

2. Specialized PEI Expertise & Equipment​

• 100+ Ultem Molds Built Annually: We design and manufacture over 100 custom molds for PEI each year—more than most competitors—giving us deep experience in optimizing mold flow for PEI’s unique viscosity. Our molds include features like hot runners (to reduce scrap) and conformal cooling (for uniform part quality).​

• 380 °C Capable Presses: Our fleet of 20 injection molding machines is specially modified to reach 380 ° C. (critical for melting PEI) and maintain ±1 °C temperature precision. Each machine has low-shear screw design to protect PEI’s polymer chains from degradation.​

• In-House Rheology & FEA: Our rheology lab tests PEI melt flow and viscosity before every run to ensure consistency. We also use Finite Element Analysis (FEA) to simulate part performance (НАПРИМЕР., теплостойкость, стресс) during design—eliminating costly trial-and-error.​

3. Скорость & Flexibility for Fast-Moving Markets​

• 48-Hour T1 Sampling: We deliver first-article samples (T1) в 48 hours for most PEI projects—using rapid prototyping tools (НАПРИМЕР., high-temperature 3D printing) to validate designs fast. This cuts new product development time by 4–6 weeks.​

• Automated Degating & Производство: Our robotic degating systems reduce cycle times by 20–25% and ensure consistent part quality—critical for high-volume orders (НАПРИМЕР., 100,000+ aerospace clips).​

• Custom Formulations: We create tailored PEI grades (НАПРИМЕР., ESD PEI, radiopaque PEI) for unique needs—something off-the-shelf grades can’t match. Например, we developed a PTFE-modified PEI for a client’s industrial pumps that resists oil degradation 3x better than standard PEI.​

4. Reliable Supply Chain & Устойчивость

• Global Sabic Distributor Pact: We have an exclusive partnership with Sabic (the leading PEI manufacturer) to ensure priority access to grades like Sabic Ultem 1000, Medical Ultem HU, и Aerospace Ultem 9085—even during material shortages. This guarantees consistent lead times (4–6 weeks for production runs) and stable pricing.​

• Sustainable Low-Waste Molding: We reuse PEI scrap (from runners and prototypes) Для некритических частей, keeping material waste below 5% (против. 10–15% industry average). Our machines use energy-efficient heating systems that cut electricity use by 20%, reducing our carbon footprint.​

• Lifetime Tool Warranty: We offer a lifetime warranty on all PEI molds we build—covering wear parts (НАПРИМЕР., сопла, ejectors) and design defects. This saves clients ​5,000–10,000 in mold maintenance costs over a tool’s 500,000+ cycle life.​

5. Сквозная поддержка & IP Protection​

• IP Protection Framework: We sign strict non-disclosure agreements (А) for all custom projects and limit access to client designs to authorized engineers only. For startups and companies with proprietary technology, we also offer confidentiality clauses in manufacturing contracts.​

• 24/7 Technical Hotline: Our PEI experts are available 24/7 to troubleshoot issues (НАПРИМЕР., part warping, отклонение размеров) and adjust processes—minimizing production downtime. We also provide post-delivery support, including part performance testing and optimization.​

Design-for-Manufacturability (DFM) Поддерживать: Our engineers review client designs early to suggest tweaks that improve PEI processability (НАПРИМЕР., adding draft angles to reduce warping, optimizing wall thickness for uniform cooling). This reduces tooling revisions by 50% and cuts costs by 10–15%.

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