Custom PEEK Injection Molding Supplier In China
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PEEK Injection Molding Manufacturer
Stebro Mold is your ultimate destination for high-quality PEEK plastic injection molding services. We work with many industries, including medical, aerospace, and automotive. Our team offers precise solutions to help you improve your products and meet strict standards. When you choose Stebro Mold, you work with experts who deliver great work on time and on budget.
Our services include:
- 2D & 3D product design and optimization
- The material selection
- Rapid prototyping services
- Cost-effective mold solution
- Mold Flow Analysis to optimize the mold design
- In-house tooling manufacturing, tooling transfer, mold change, and maintenance
- PEEK injection mold trial
- Low Volume production runs and mass production for PEEK components
PEEK Parts Assembly
Why Stebro Mold
- Free Plastic Part Design Assistance
- Mold design optimize with Moldflow to improve the surface and reduce cost
- In-house Mold Manufacturing
- Life Guarantee, Free Maintenance
- Affordable Price, No Hidden Charges
- Quality Control In Manufacturing, Consistent Quality
- On Time Delivery
- 24-Hour Quote Responses With DFM Feedback
- Engel Injection Molding Machine for PEEK Molding
Material & Applications
PEEK material is a high-performance polymer. It is widely used due to its excellent mechanical properties, thermal stability, and chemical resistance properties. Its semi crystalline structure gives it extra strength and durability. Learn more about the properties of peek, which make it ideal for many uses in industries:
Aerospace:
- Lightweight structural components, such as gears, bearings, and seals
- Electrical connectors and cable insulation for aircraft wiring systems
Automotive:
- High-performance parts, including pistons, seals, and valve components
- Electric vehicle (EV) battery components and housings
Medical:
- Implants, such as spinal fusion devices and joint replacement components
- Surgical instruments, like forceps and endoscopic devices
- Medical device housings and enclosures
Oil and Gas:
- Downhole tools and components, like seals, gaskets, and valve parts
- Compressor and pump components
Electronics:
- Insulation for high-temperature electronics, such as circuit boards and connectors
- Semiconductor manufacturing equipment components
injection molded peek properties
- High-temperature resistance: With a continuous service temperature of 250°C and a melting point of around 343°C
- Chemical resistance: It is resistant to a wide range of chemicals, including acids, bases, and organic solvents.
- Mechanical strength: It has high tensile and flexural strength.
- Electrical properties: It exhibits excellent electrical insulation and low dielectric constant over a wide frequency range.
- Biocompatibility: Suitable for sterilization and safe for medical applications.
- Wear and abrasion resistance
- Lower energy consumption
Cost Considerations
There are lots of PEEK injection molding manufacturers in China. The cost from different peek injection molding suppliers is different. The price mainly depends on material cost, mold manufacturing, cycle times, production volume, and secondary operations. If you want to get the accurate PEEK plastic parts price, you can contact the PEEK injection molding factory in China.
Molding Tolerances
Tight tolerances with PEEK injection molding requires a combination of proper part geometry, mold design, precise tooling, and optimal processing conditions. We have to consider shrinkage, warpage, and cooling rates to ensure the desired tolerances are maintained throughout the production. In some cases, secondary operations, such as CNC machining or surface finishing, may be required to achieve tighter tolerances if necessary.
PEEK Injection Molding Guide
Part Design
Plastic Material Selection:
Choose the appropriate grade of PEEK based on demanding application requirements—including chemical resistance, mechanical strength, and thermal performance. Consider the material’s behavior under high temperatures and its suitability for your specific operating environment.
Wall Thickness:
- Guideline: Maintain a uniform wall thickness to promote even cooling and minimize internal stresses.
- Recommendation: For the PEEK injection molded parts, aim for ~1 mm for small parts and ~4 mm for larger parts.
- Best Practice: Consistent wall thickness reduces warpage and helps control shrinkage (typically 0.5–2%).
Draft Angles:
- Guideline: Use 1–3° draft angles to facilitate part ejection and reduce the risk of mold wear or part damage.
- Best Practice: Avoid abrupt transitions; smooth, gradual changes minimize stress concentrations.
Ribs and Gussets:
- Guideline: Integrate ribs and gussets to reinforce the part without adding extra thickness.
- Recommendation: Keep rib thickness to 60–70% of the nominal wall thickness to prevent sink marks and internal stresses.
Radii and Fillets:
- Guideline: Add generous radii and fillets to sharp corners and transitions.
- Best Practice: Gradual transitions promote uniform material flow and reduce stress concentrations, enhancing part strength.
Transition Features:
- Action: Ensure all changes in geometry are gradual rather than abrupt, using filleted edges to maintain consistent material distribution throughout the part.
Mold Design
Tooling Steel:
- Recommendation: Use high-performance steels such as S7 or H13 to withstand PEEK’s high processing temperatures and abrasive nature.
Shrinkage and Warpage:
- Guideline: Account for a 0.5–2% shrinkage rate by maintaining uniform wall thickness and employing an optimized cooling channel layout.
- Best Practice: Use simulation (e.g., Mold Flow Analysis) to predict and mitigate warpage.
Runner and Sprue Design:
- Action: Design runners and sprues to balance material flow, minimize pressure loss, and ensure even cavity filling.
- Best Practice: Optimize dimensions and layout to reduce the occurrence of weld lines and material degradation.
Gate Location and Type:
- Guideline: Optimize gate type, size, and placement for balanced filling.
- Recommendation: Consider using edge or submarine gates to reduce weld lines and improve flow balance.
Cooling System:
- Action: Design an efficient cooling system with strategically placed cooling channels to ensure uniform temperature distribution.
- Best Practice: Effective channel and vent placement minimizes cycle times and warpage.
Venting:
- Guideline: Add enough vents at the ends of flow paths and high-pressure areas. This helps trapped air escape. It prevents short shots and surface defects.
Ejection System:
- Action: Create an ejection system. Use ejector pins, stripper plates, or sleeve ejection. This will help remove parts smoothly without causing stress or damage.
Thermal Expansion Considerations:
- Guideline: Design for PEEK’s thermal expansion by providing appropriate clearances and tolerances to accommodate expansion during processing.
Mold Surface Finish:
- Recommendation: Use a smooth, polished surface. This will help material flow better and reduce defects. It will also lower mold wear.
Mold Maintenance:
- Best Practice: Design molds for ease of disassembly, cleaning, and routine inspection to maintain consistent quality over production cycles.
PEEK Injection Molding Guide
Equipment Setup
- Drying Machine:
- Action: Use a drying machine to dry PEEK at 300–350°F (150–177°C) for 3 to 4 hours. This will lower the moisture content to below 0.02%. Doing this helps prevent degradation and defects.
- Injection Molding Machine:
- Requirement: Ensure the machine can consistently handle high-temperature processing conditions suitable for PEEK.
- Screw and Barrel:
- Recommendation: Use parts made of special tool steel or coated with wear-resistant materials. This is important when working with filled PEEK grades.
- Hot Runner System (Optional):
- Action: Think about using a hot runner system. This can help reduce material waste and improve cycle times. Make sure it works well with PEEK’s high processing temperatures and is easy to maintain.
- Temperature Control System:
- Action: Integrate a precise temperature control system to maintain consistent processing temperatures and avoid material degradation.
- Mold Temperature Controller:
- Action: Employ a dedicated mold temperature controller for even cooling across the mold.
Injection Molding Parameters:
Material Preparation:
- Action: Thoroughly dry PEEK at 300–350°F (150–177°C) for 3–4 hours to achieve moisture content below 0.02%.
Mold Temperature:
- Set the temperature between 250°F and 350°F (121°C to 177°C). This helps the material flow well and stay stable. It also reduces warping.
Melt Temperature:
- Recommendation: Set the barrel temperature between 650°F and 750°F (343°C to 399°C). For filled grades, raise the temperature a bit. Keep the nozzle temperature slightly lower to avoid drooling.
Injection Speed:
- Action: Use moderate injection speeds to maintain uniform cavity filling and minimize material degradation. Avoid overly rapid or slow speeds.
Injection Pressure:
- Guideline: Typically range between 69–138 MPa to ensure complete cavity filling while minimizing voids and short shots.
Hold Pressure and Time:
- Action: Apply a hold pressure of 5,000 to 15,000 psi (34 to 103 MPa). Use this pressure for a time that fits the part’s size and shape. This helps reduce shrinkage and sink marks.
Cooling Time:
- Action: Improve cooling time by considering part size, wall thickness, and mold temperature. This will help achieve even cooling and shorter cycle times.
Process Monitoring:
- Best Practice: Use real-time monitoring for key factors like temperature, pressure, and injection speed. This helps make quick adjustments and keeps conditions optimal during the molding process.
Follow these guidelines to optimize your PEEK injection molding process for top-quality injection molded PEEK parts and efficient production. Every project is unique—adapt these recommendations to your specific needs. For reliable service and competitive pricing, contact our team, your trusted PEEK injection molding supplier in China today.