Piper Plastics (Chandler, AZ) reports that it has developed a proprietary high-pressure molding technology that yields near-net-shape polymers up to 2 inches thick without porosity, voids or sinks.

The NexPET system can run up to a 48-cavity mold and is equipped with a number of productivity-enhancing features. In particular, Husky cites the following:

A major reason for developing the new technology was to save costs when machining finished parts from expensive, high-performance materials such as PEEK, PAI or TPI, said the company. “The molds are inexpensive, since we are only molding a near-net shape that will be machined after molding,” said Bruce White, Vice President, Piper Plastics. “Because it’s close to the final part, a near-net shape requires less machining. Less machining means less waste, which is an important consideration for green and sustainable programs.”

The technology also allows Piper to offer small batch runs for mating the right polymer or blend for an application. “Distributors typically only carry about 50 types of engineering plastics, but with this technology we can mold custom blanks from more than 3,000 polymers and compounds, or develop a compound specifically for an application,” said White.

A subsidiary of Quadrant Engineering Plastic Products, Piper Plastics supplies high-performance polymer materials and precision machined plastic components and assemblies to a range of industries.

The preform system benefits both established companies producing niche brands or smaller-run SKUs as well as emerging producers seeking a fast, low-risk entry into markets, said Husky. It also allows manufacturers to respond nimbly to shifting market trends, such as greater consumer demand for personalized products. COVID-19 has amplified this trend globally, according to Robert Domodossola, President, Rigid Packaging. The pandemic has forced many producers to “rapidly adapt operations to scale up new applications like hand sanitizer, disinfectant, and other health, personal care, or cleaning related products,” said Domodossola.

The NexPET system will benefit established companies producing niche brands or smaller-run SKUs as well as emerging producers seeking a fast, low-risk entry into markets, said Husky.

Husky Injection Molding Systems’ new NexPET system is described by the company as a game-changing mid-volume PET preform molding solution. It is designed to help producers introduce multiple new applications into the market quickly and cost effectively.

The process, which utilizes molding equipment designed and developed by Piper Plastics, allows the company to mold filled or unfilled high-performance thermoplastics with isotropic mechanical properties. “This capability is especially beneficial for large CNC machined parts that were historically limited to extruded or compression molded stock shapes,” explained Dave Wilkinson, Materials Engineering Manager, in a prepared statement. “In comparison to extrusion and compression molding, this new process yields parts that have higher strength—typically 15 to 20% stronger than extruded shapes and 50% stronger than compression molded shapes—with more consistent mechanical properties.”

The process is suitable for large parts and weights up to 6 pounds per blank, with large and varying wall thicknesses and complex geometries. “Near-net shape is effective for parts that cannot be produced using standard injection molding because the cross sectional area is too thick,” said Wilkinson. “This new technology has opened up exciting opportunities in the semiconductor, oil and gas, medical equipment and aerospace markets.”