Consider the material requirements for your parts. Both low volume injection molding and thermoforming offer versatility in material selection, with a wide range of thermoplastic resins available. Evaluate factors such as material properties, performance requirements, and cost to determine the most suitable material for your application.

PPS, which stands for polyphenylene sulfide, is another high-performance engineering thermoplastic that is known for its excellent mechanical properties, high heat resistance, and chemical resistance. It is often used in automotive, electrical, and electronic applications due to its excellent electrical insulation properties and resistance to corrosion.

Injection moulding is a widely used manufacturing process that involves the creation of parts and products by injecting molten material into a metal mould. This process is ideal for producing high-volume, complex components with great precision and repeatability. Because the process involves taking the polymer into a molten state and maintaining it there until it is injected into the mould, it requires careful consideration and equipment that is capable of managing the polymer in its liquid state. Well known polymers – such as polypropylene, polyethylene, and even nylons – are relatively easy to handle in this process. Not only do they melt at relatively low temperatures (anywhere between 150-175°C) but they are also fairly easy to handle when liquid, as they do not give off any corrosive gaseous effluents. They also have very predictable melt-flows and shrinkages, meaning that a part can be quickly developed using off-the-shelf metrics that can usually be provided by the raw material suppliers.

In contrast, low volume injection molding often employs aluminum molds, operating at lower pressures to safeguard against mold damage. This strategic choice significantly reduces tooling costs by 5 to 25 percent, with aluminum's malleability facilitating quicker mold creation, thereby expediting the overall injection molding process timeline.

Resistance to heat and chemicals: PEEK and PPS both have excellent resistance to heat and chemicals, making them ideal for use in harsh environments. Injection moulded parts made from these materials can withstand high temperatures and exposure to corrosive chemicals without degrading, which can increase the longevity of the parts and reduce maintenance costs.

Biocompatibility: PEEK is biocompatible, meaning that it is compatible with human tissue and can be used in medical applications such as implants. This makes it an excellent choice for medical device manufacturers who need to create parts that are both strong and biocompatible.

Thermoforming is a versatile manufacturing process involving the heating of large plastic sheets until pliable, which are then shaped around a custom-fabricated aluminum tool.

Whether you need 1,000 or 100,000 custom plastic components, the thermoforming experts at Advanced Plastiform Inc. will work with you to determine the best method of manufacturing to provide you with the durable, high-quality plastics you need. This includes prioritizing a low per-unit price with as quick a lead time as possible.

Precision and repeatability: Injection moulding allows for the creation of highly precise parts with excellent repeatability. This means that each part will be identical to the next, which is important in applications where consistency is critical.

Despite the benefits of the end-products, the issue with both these polymers – as well as other high-temperature plastics such as PEI, PEK, and Polyimide (PI) – is that they are not straightforward to mould. For one, the melting points are far higher than those of regular polymers, meaning that the equipment and moulds need to be able to hold the polymer at a consistent temperature in excess of 400°C. The matter is further complicated by the effluent gases generated by these polymers when in a molten state. Some of these gases can be extremely corrosive, causing damage to the regular metal barrels within which they will be held before injection. Finally, the melt flow of these polymers, while consistent, needs to be understood properly before moulding. To compound the issues, polymers such as PEEK and PPS are expensive, costing anywhere from 20X to 50X the price of regular plastics. Hence, the room for trial-and-error is limited and the equipment itself needs to be made such that wastages are minimised.

Compare the tooling costs and lead times associated with each method. Low volume injection molding typically requires the fabrication of aluminum molds, which offer cost savings and shorter lead times compared to steel molds used in traditional injection molding. Thermoforming molds are also cost-effective and can be fabricated more swiftly due to their single-sided design and lightweight materials.

Evaluate the complexity of the parts you need to manufacture. Low volume injection molding excels in producing parts with intricate details, tight tolerances, and complex geometries, making it suitable for applications requiring high precision. Thermoforming is better suited for larger parts with simpler geometries, although pressure forming techniques can achieve finer details compared to traditional vacuum forming.

Consider your project timeline and production speed requirements. Thermoforming typically offers faster lead times and shorter production cycles compared to low volume injection molding, making it a preferred choice for rapid prototyping and quick-turn projects. However, if precision and tight tolerances are critical, low volume injection molding may be the better option despite longer lead times.

Lightweight: PEEK and PPS are both lightweight materials, which can reduce the overall weight of the finished product. This can be especially beneficial in applications where weight is a concern, such as aerospace or automotive applications.

Take into account the size and weight of the parts you need to produce. Thermoforming is well-suited for forming large parts with minimal material thinning, making it ideal for applications requiring lightweight yet durable components. Low volume injection molding can also accommodate a range of part sizes but may be more suitable for smaller, more intricate parts.

Electrical insulation: PPS is an excellent electrical insulator, which makes it ideal for use in electrical and electronic applications where insulation is critical. Injection moulded parts made from PPS can provide excellent insulation properties, which can help to protect sensitive electronic components.

This approach not only reduces initial investment but also enhances the overall flexibility and scalability of the thermoforming process, making it well-suited for low to mid-volume production runs.

Resistance to wear and tear: PEEK and PPS both have excellent resistance to wear and tear, which can increase the longevity of parts and reduce maintenance costs. Injection moulded parts made from these materials can withstand high levels of wear and tear without degrading, which can be especially beneficial in applications where the parts are exposed to abrasive materials.

At Poly Fluoro, we have harnessed our existing knowhow on PEEK compression moulding and our experience with injection moulding polymers such as POM, Nylon, and polypropylene to develop a new equipment only for high-temperature polymers such as PEEK and PPS.

Since 1988, Advanced Plastiform, Inc., has been providing superior custom plastic molding and fabrication services to companies in North Carolina, South Carolina, Maryland, Georgia and Pennsylvania. Contact us to make an appointment Mon-Fri 8-5.

We proudly serve the Mid-Atlantic and Southeast, including North Carolina, South Carolina,  Pennsylvania, Maryland, Tennessee, Georgia, and Virginia.

Thermoforming boasts several advantages that make it an attractive plastic manufacturing method for low- to mid-volume production:

Low volume injection molding finds application across a wide range of industries where precision, flexibility, and cost-effectiveness are paramount. Some of the key industries utilizing low volume injection molding include medical, telecommunications, consumer packaging, and more.

It is therefore important that injection moulding presses that are capable of handling these high-performance plastics are specially constructed. Metal housings and other components must be designed to withstand the corrosion, stress, and temperatures of the polymers in their molten state.

After cooling, the mold opens, and the newly formed plastic part is ejected. Depending on the complexity of the part and the requirements of the project, secondary operations such as trimming, machining, or assembly may be performed to achieve the final desired product.

Get started today by receiving a free quote tailored to your project for plastic parts and products. Contact us now by calling us at  919-404-2080 or filling out the online contact form. Don't delay—unlock the potential of custom plastics manufacturing with us today.

PEEK, which stands for polyetheretherketone, is a high-performance engineering thermoplastic that is known for its exceptional strength, stiffness, and heat resistance. It has excellent chemical resistance, which makes it ideal for use in harsh chemical environments. PEEK is often used in aerospace, automotive, and medical applications due to its high strength-to-weight ratio, biocompatibility, and resistance to wear and tear.

Traditional plastic injection molding is renowned for its high-volume manufacture but entails significant upfront costs, primarily due to tooling expenses. Injection molds, usually crafted from steel or copper alloy, endure the intense pressures of the injection process, necessitating intricate and heavyweight designs, thereby escalating fabrication costs and lead times.

Thermoforming often utilizes lightweight aluminum molds, minimizing both tooling costs and lead times. Thermoforming molds are typically single-sided and can be fabricated more swiftly due to the material's malleability, making it an efficient and cost-effective alternative to traditional injection molding.

Low volume injection molding offers several distinct advantages that make it a preferred choice for small to medium-sized production runs:

Injection moulding is a widely used manufacturing process that involves the creation of parts and products by injecting molten material into a metal mould. This process is ideal for producing high-volume, complex components with great precision and repeatability. Because the process involves taking the polymer into a molten state and maintaining it there until it is injected into the mould, it requires careful consideration and equipment that is capable of managing the polymer in its liquid state. Well known polymers – such as polypropylene, polyethylene, and even nylons – are relatively easy to handle in this process. Not only do they melt at relatively low temperatures (anywhere between 150-175°C) but they are also fairly easy to handle when liquid, as they do not give off any corrosive gaseous effluents. They also have very predictable melt-flows and shrinkages, meaning that a part can be quickly developed using off-the-shelf metrics that can usually be provided by the raw material suppliers. Two materials that are less commonly used in injection moulding are PEEK and PPS. However, considering the immense advantages of these plastics, it is worth exploring how and why they are excellent candidates for injection moulding. PEEK, which stands for polyetheretherketone, is a high-performance engineering thermoplastic that is known for its exceptional strength, stiffness, and heat resistance. It has excellent chemical resistance, which makes it ideal for use in harsh chemical environments. PEEK is often used in aerospace, automotive, and medical applications due to its high strength-to-weight ratio, biocompatibility, and resistance to wear and tear. PPS, which stands for polyphenylene sulfide, is another high-performance engineering thermoplastic that is known for its excellent mechanical properties, high heat resistance, and chemical resistance. It is often used in automotive, electrical, and electronic applications due to its excellent electrical insulation properties and resistance to corrosion. There are many benefits to using injection moulded parts made from PEEK and PPS, some of which include: High strength and stiffness: PEEK and PPS are both known for their exceptional strength and stiffness. Injection moulded parts made from these materials can withstand high loads and stresses without deforming or breaking, making them ideal for use in high-stress applications. Resistance to heat and chemicals: PEEK and PPS both have excellent resistance to heat and chemicals, making them ideal for use in harsh environments. Injection moulded parts made from these materials can withstand high temperatures and exposure to corrosive chemicals without degrading, which can increase the longevity of the parts and reduce maintenance costs. Precision and repeatability: Injection moulding allows for the creation of highly precise parts with excellent repeatability. This means that each part will be identical to the next, which is important in applications where consistency is critical. Lightweight: PEEK and PPS are both lightweight materials, which can reduce the overall weight of the finished product. This can be especially beneficial in applications where weight is a concern, such as aerospace or automotive applications. Biocompatibility: PEEK is biocompatible, meaning that it is compatible with human tissue and can be used in medical applications such as implants. This makes it an excellent choice for medical device manufacturers who need to create parts that are both strong and biocompatible. Electrical insulation: PPS is an excellent electrical insulator, which makes it ideal for use in electrical and electronic applications where insulation is critical. Injection moulded parts made from PPS can provide excellent insulation properties, which can help to protect sensitive electronic components. Resistance to wear and tear: PEEK and PPS both have excellent resistance to wear and tear, which can increase the longevity of parts and reduce maintenance costs. Injection moulded parts made from these materials can withstand high levels of wear and tear without degrading, which can be especially beneficial in applications where the parts are exposed to abrasive materials. Despite the benefits of the end-products, the issue with both these polymers – as well as other high-temperature plastics such as PEI, PEK, and Polyimide (PI) – is that they are not straightforward to mould. For one, the melting points are far higher than those of regular polymers, meaning that the equipment and moulds need to be able to hold the polymer at a consistent temperature in excess of 400°C. The matter is further complicated by the effluent gases generated by these polymers when in a molten state. Some of these gases can be extremely corrosive, causing damage to the regular metal barrels within which they will be held before injection. Finally, the melt flow of these polymers, while consistent, needs to be understood properly before moulding. To compound the issues, polymers such as PEEK and PPS are expensive, costing anywhere from 20X to 50X the price of regular plastics. Hence, the room for trial-and-error is limited and the equipment itself needs to be made such that wastages are minimised. It is therefore important that injection moulding presses that are capable of handling these high-performance plastics are specially constructed. Metal housings and other components must be designed to withstand the corrosion, stress, and temperatures of the polymers in their molten state. At Poly Fluoro, we have harnessed our existing knowhow on PEEK compression moulding and our experience with injection moulding polymers such as POM, Nylon, and polypropylene to develop a new equipment only for high-temperature polymers such as PEEK and PPS. Overall, injection moulded parts made from PEEK and PPS offer many benefits over other materials. They are highly durable, resistant to heat and chemicals, and can be used to create highly precise parts with excellent repeatability. They are also lightweight, biocompatible, and offer excellent electrical insulation properties. There is a world of applications and we at Poly Fluoro, as always, are at the forefront. Read More 1. PTFE Seals in Food Processing 2. Expanded PTFE (ePTFE) Gasket Tapes - Applications in Electrolysers 3. Polymer Scraper Blades - An effective, non-damaging solution to automation systems

With a commitment to precision, efficiency, and cost-effectiveness, our injection molding company specializes in providing comprehensive solutions tailored to your unique plastic part needs. Whether you're aiming for intricate details with low volume injection molding or seeking the versatility of thermoforming, our expertise ensures that you can make informed decisions to propel your project forward with confidence.

High strength and stiffness: PEEK and PPS are both known for their exceptional strength and stiffness. Injection moulded parts made from these materials can withstand high loads and stresses without deforming or breaking, making them ideal for use in high-stress applications.

Navigating the realm of manufacturing processes can be a daunting task, especially when considering options like low volume injection molding or thermoforming. At Advanced Plastiform Inc., we understand the critical importance of choosing the right method for your project.

Advanced Plastiform offers guidance on the optimal manufacturing process to maximize efficiency and cost-effectiveness for low run, plastic parts.

The low volume injection molding process begins with the creation of a custom-designed injection mold. The mold is then mounted onto an injection molding machine, where thermoplastic pellets are fed into a heated barrel within the machine, where they are melted to a liquid state. The molten plastic is then injected under high pressure into the mold cavity, conforming to its shape and intricacies.

Two materials that are less commonly used in injection moulding are PEEK and PPS. However, considering the immense advantages of these plastics, it is worth exploring how and why they are excellent candidates for injection moulding.

Choosing between low volume injection molding or thermoforming methods requires careful consideration of various factors to ensure the optimal manufacturing solution for your specific project requirements.

Twin sheet forming is an advanced technique where two plastic sheets are heated simultaneously and formed together to create a hollow, double-walled structure, offering enhanced strength, insulation, and structural integrity for applications such as automotive components, farming equipment, outdoor furniture, and more.

Overall, injection moulded parts made from PEEK and PPS offer many benefits over other materials. They are highly durable, resistant to heat and chemicals, and can be used to create highly precise parts with excellent repeatability. They are also lightweight, biocompatible, and offer excellent electrical insulation properties. There is a world of applications and we at Poly Fluoro, as always, are at the forefront.

Consider the anticipated production volume for your project. Low volume injection molding is typically suited for production runs of fewer than 10,000 pieces, making it ideal for smaller quantities. Thermoforming, on the other hand, offers flexibility for both low to mid-volume production runs, with the ability to scale up or down as needed.

Vacuum forming involves suctioning out the air between the plastic sheet and the tool to ensure a snug fit, ideal for larger pieces with less intricate details. Conversely, pressure forming utilizes highly pressurized air to blast the plastic sheet while simultaneously applying vacuum suction, allowing for sharper angles and finer details, making it a compelling alternative to injection molding.

Low volume injection molding, also known as "short-run manufacturing," serves as the vital bridge between product prototyping and high-volume production, catering to orders typically fewer than 10,000 pieces.