thin film laminate composites - peek injection molding

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PEEK also has low moisture absorption, stable dielectric (insulating) properties and inherently low flammability. The amazing thing about PEEK is the wide range of processing options from injection molding, compression molding, and extrusion into shapes, film or fibers, to thermoforming, spray coating, or stock shape machining – it is truly one of the most versatile structural materials available.

Some of the first VICTREX PEEK applications were wear components for industrial equipment such as seal rings, bushings, bearings and valves, especially in extreme environments. Hydraulic valves in automotive anti-lock brake systems started in Europe and quickly became a global industry standard.

By combining supercritical fluid with its original molding technology, Toppan is able to achieve a 30% reduction in wall thickness without compromising strength.

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The new container is part of Toppan’s Sustainable-Value Packaging lineup. Samples were made available in Japan starting Feb. 24 to manufacturers in the foods and toiletries sectors.

Carbon Steel, Stainless Steel, Titanium, Aluminum, Magnesium, Brass and Bronze have all been replaced with VICTREX PEEK over the years.

John Walling, Strategic Marketing Manager for Victrex Polymer Solutions, talks to AZoM about metal replacement with PEEK (polyetheretherketone).

By improving resin fluidity, the technology also enables the use of more eco-friendly plastics, such as biodegradable resins and biomass polyethylene, which are typically difficult to mold. The reduction in thickness does not compromise strength.

Ultra-thin-wall molding presents challenges in terms of cost, durability, and the feasibility of mass production, said Toppan. Thermoforming has generally been considered a better option for the production of thin-walled containers, but it does not offer the same design possibilities as injection molding, noted the company.

Victrex plc.. 2019. Replacing Metals with PEEK (Polyetheretherketone). AZoM, viewed 29 September 2024, https://www.azom.com/article.aspx?ArticleID=10147.

The technology allows the wall thickness of injection molded products to be reduced by approximately 30%, from 0.5 to 0.35 mm. In addition to a reduction in plastics consumption, the process and also helps to lower CO2 emissions associated with resin manufacture.

The beauty of the injection molding process, once mastered, is that it can be optimized for faster processing cycles and easy part-to-part repeatability which means lower overall costs compared to metals.

Until she retired in September 2021, Clare Goldsberry reported on the plastics industry for more than 30 years. In addition to the 10,000+ articles she has written, by her own estimation, she is the author of several books, including The Business of Injection Molding: How to succeed as a custom molder and Purchasing Injection Molds: A buyers guide. Goldsberry is a member of the Plastics Pioneers Association. She reflected on her long career in "Time to Say Good-Bye."

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VICTREX PEEK can improve fuel economy and reduce emissions in two ways. First, by reducing energy losses due to excess weight, and second, by reducing friction losses in the powertrain. A 68% weight reduction in gears, for example, results in a 78% reduction in the moment of inertia which leads to a 9% increase in efficiency. The reason: low weight – i.e. reduced moving masses – and the lower friction losses typical of plastic, both of which help considerably when optimising response or when accelerating or decelerating masses.

Simply put, PEEK is “best all around” when it comes to high performance and processing versatility. PEEK (polyetheretherketone) is a semi-crystalline thermoplastic with a linear aromatic polymer structure. The fully recyclable material melts at 343°C and possesses exceptional mechanical properties with resistance to chemicals, wear, fatigue and creep even at high operating temperatures where it is commonly used in service.

Greater design freedom comes from PEEK’s amazing processing versatility which allows complex geometries to be molded-in without labor intensive post-machining steps. This, in turn, helps engineers improve on performance while reducing total system cost.

Victrex plc.. "Replacing Metals with PEEK (Polyetheretherketone)". AZoM. https://www.azom.com/article.aspx?ArticleID=10147. (accessed September 29, 2024).

The global semiconductor market has entered an exciting period. Demand for chip technology is both driving the industry as well as hindering it, with current chip shortages predicted to last for some time. Current trends will likely shape the future of the industry, which is set to continue to show

Victrex plc.. (2019, May 30). Replacing Metals with PEEK (Polyetheretherketone). AZoM. Retrieved on September 29, 2024 from https://www.azom.com/article.aspx?ArticleID=10147.

“This new technology enables the production of containers that offer all the benefits of conventional injection molding but with a reduced impact on the environment,” said Toshiaki Kakemura, General Manager of Plastic Development in Toppan’s Packaging Solutions business. “We will expand sales to manufacturers of food and toiletries and continue to drive sustainable solutions for society and growth for our customers’ businesses through the Toppan S-Value Packaging range.”

The primary distinction between graphene-based batteries and solid-state batteries lies in the composition of either electrode. Although the cathode is commonly changed, carbon allotropes can also be employed in fabricating anodes.

"While heavier metals were first replaced with aluminium, titanium and magnesium, we now see engineers looking to further optimize their designs by replacing these “light metals” with VICTREX® PEEK. We now have over 35 years of experience in working with customers on metal replacement and a growing list of applications across all industries."

John Walling is the Americas Strategic Marketing Manager for Victrex Polymer Solutions.  He holds a Bachelor of Mechanical Engineering Degree from the University of Michigan and a Masters in Business Administration from the Anderson School at UCLA.

Tokyo-based Toppan Printing has combined the use of a supercritical fluid — a substance at a temperature and pressure above its critical point that has both gas and liquid properties — with its original molding technology to develop an ultra-thin-walled container that is roughly 30% thinner than a conventional injection molded product.

One recent case study highlights the benefits of metal replacement in aircraft system attachment clamps. One of the world’s leading suppliers of interconnect products has worked to replace aluminum and stainless steel in their line of wire and tubing clamps. One electrical wire bundle clamp made with VICTREX PEEK is 20% lighter than the aluminum clamp it replaced.

Victrex plc.. "Replacing Metals with PEEK (Polyetheretherketone)". AZoM. 29 September 2024. .

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The need for high wear performance combined with heat and chemicals translated into high purity environments such as food, beverage and semiconductor industries where electrostatic dissipative (ESD) PEEK compounds were developed for wafer handling in IC chip fabrication.  Over the past two decades the number of applications for VICTREX PEEK has exploded to include aircraft brackets, clamps and insulation, oil drilling tool seals and connectors, transmission gears, and now even more into consumer applications like vacuum impellers, refrigerator compressors, and mobile device speakers.

John has more than 20 years of experience with high performance polymer and composite material suppliers serving in various technical and market development roles with GE Plastics and Owens Corning Composites Systems prior to joining Victrex in 2003.

Not only is PEEK a lightweight solution, it also provides a productivity solution in manufacturing with the opportunity to consolidate and simplify part designs through the injection molding process. Designing with thermoplastics like PEEK allows engineers to take a current metal component, re-visit the design, and simplify it to make it easier on the installation and manufacturing teams at the tier and OEM level.

Toppan’s technology makes it possible to exceed the conventional limits of injection molding and form products with a reduced wall thickness akin to what can be achieved by thermoforming. The supercritical fluid is dissolved in molten resin to ensure that it efficiently reaches every corner of the injection mold, enabling the production of lighter containers with thinner walls.

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Absolutely. Victrex is committed to developing advanced materials that leverage our knowledge and expertise with polyketones. We are led by market needs and look to innovate with our customers who are leaders in their respective industries. With a focus on solving challenging engineering problems, we have identified several unmet needs that can be addressed by new polymers that we are actively working on.

The inherent low specific gravity of VICTREX PEEK (1.3 g/cm3) is less than half that of aluminium and one sixth that of steel. Carbon or glass fibers are added as structural reinforcements in PEEK compounds that have high strength and modulus properties similar to aluminium, but still much lower in density. This results in a superior strength-to-weight ratio so VICTREX PEEK-based compounds can offer equivalent strength and stiffness with up to 70% weight reduction.

You can find a wealth of information and regional contacts at our website or you can follow us on LinkedIn to learn about new products and applications. We will also be exhibiting at the K Show in Dusseldorf, Germany from Oct. 16-23, so please come visit us at Hall 5, Booth A23!

There are approximately 15,000 clamps used to secure the wiring and cables on a given plane which results in substantial weight savings. This translates to $23,000 per year in fuel savings as well as a CO2 emission reduction of 80 tons for each plane using this technology. Not only can this application help save airlines money and reduce air travel’s effect on the environment, but the clamps are much easier to install.

While the automotive industry drives for weight reduction to achieve increased fuel efficiency needed to meet aggressive government mandates, noise reduction and low maintenance are also important design goals. In the gear example, noise, vibration, and harshness was lowered by 3dB – this is equivalent to a 50% noise level reduction for the human ear.

The switch from metal to plastic injection molding allowed for a re-design that led to the integration of a new locking hinge that helped reduce installation times by 30%. The “lock-open, lock-closed” feature of the clamp provides manufacturers with the opportunity to install the clamps with one hand leaving the other free for other tasks. This really demonstrates how VICTREX PEEK is solving multiple problems to gain acceptance versus metal in one of the world’s most conservative industries.

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Besides weight reduction, we see three more major benefits: enhanced performance, greater design freedom, and lower total system cost. Enhanced performance benefits include everything from extending lifetime by eliminating corrosion, increasing fuel efficiency with lower friction, and handling higher loads/speeds to operating in more extreme chemical environments.