An Informational Brief on Polymer Machining

 

Since it was first polymerized in 1954 by Karl Rehn and Giulio Natta, polypropylene (PP) has become one of the leading polymer choices for a wide array of applications from automotive to commercial to medical.

 

Polypropylene plays a significant role in medical applications due to its high chemical resistance, lightweight, radiolucency and repeated autoclavability. Furthermore, medical grade PP exhibits good resistance to steam sterilization and moisture resistance. Disposable syringes, instrument or implant caddies and fluid delivery systems are the most common medical application of polypropylene. Other applications include medical vials, diagnostic devices, petri dishes, intravenous bottles, specimen bottles and surgical trays.

 

Want to learn more about the polymers we precision machine for medical applications?

 

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AIP has over 35 years of experience machining complex components from thermoplastics like polypropylene. In this insightful technical brief, we will discuss what goes into machining polypropylene and how it differs from other manufacturing options such as metal machining, injection molding, and 3D printing.

 

Homopolymer vs Copolymer – What’s the Difference?

 

The two main types of polypropylene available on the market are homopolymers and copolymers. Although they share many properties, there are some differences that help guide machinists and engineers in choosing the right material for their PP application. For the purposes of this blog, we will briefly review the differences between PP homopolymer and PP copolymer.

 

PP Homopolymer PP Copolymer
  • High strength to weight ratio and stiffer & stronger than copolymer
  • Good chemical resistance and weldability
  • Good processability
  • Good impact resistance
  • Good stiffness
  • Food contact acceptable
  • Suitable for corrosion resistant structures
  • Bit softer but has better impact strength; tougher and more durable than homopolymer
  • Better stress crack resistance and low temperature toughness
  • High processability
  • High impact resistance
  • High toughness
  • Not preferable for food contact applications

 

Properties of Polypropylene

 

Keeping information about the properties of a thermoplastic beforehand is always beneficial. This helps in selecting the right thermoplastic for an application. It also assists in evaluating if the end use requirement would be fulfilled or not. Here are some of the key properties of polypropylene:

 

Polypropylene is characterized by excellent chemical resistance in corrosive environments, resistance to cleaning agents and solvents and by a high heat deflection temperature.

 

It also has great dimensional stability and is fairly easy to machine. As noted above, it is available in heat-stabilized homopolymer and copolymer grades. At AIP, we machine POLYSTONE P, PROPYLUX HS and HS2, PROTEUS LSG HS PP from MCAM, TECAPRO MT and TECAFINE PP from Ensinger. Interesting to note is that both the PROPYLUX and TECAPRO heat stabilized PP grades are available in both standard and custom colors for medical sorting and sizing organization. Whatever your application, our machinists can help you in material selection, sizing and manufacturing techniques from concept to completion.

 

Melting Point of Polypropylene – The melting point of polypropylene occurs at a range.

 

Homopolymer: 160 – 165°C
Copolymer: 135 – 159°C

 

Density of Polypropylene – PP is one of the lightest polymers among all commodity plastics. This feature makes it a suitable option for lightweight\weight saving applications.

 

Homopolymer: 0.904 – 0.908 g/cm3
Random Copolymer: 0.904 – 0.908 g/cm3
Impact Copolymer: 0.898 – 0.900 g/cm3

 

Machining Polyproylene

 

Annealing Polypropylene

Due to its low annealing temperature, PP, like any polymer under heat and pressure, has a tendency to deform during machining. The annealing process at AIP greatly reduces the chances of these stresses occurring from the heat generated during machining PP and other polymers. Our machinists use computer controlled annealing ovens for the highest quality precision machining.

 

Machining Polypropylene

As a part of the polyolefin family, PP is semi-crystalline, which means that it can be machined at tight tolerances. We recommend non-aromatic, water-soluble coolants because they are most suitable for ideal surface finishes and close tolerances.

 

Bear in mind that polypropylene has variable levels of thermal expansion and will move a great deal with slight temperature changes. Some examples are pressurized air and spray mists. Coolants have the additional benefit of extending tool life as well.

 

Some companies machine both metals and plastics, which has detrimental outcomes for clients. Many past experiences have shown parts going to customer without cracks, only to develop cracks over time due to exposure to metal machine shop fluids. Be sure to use a facility like AIP that only machines polymers.

 

Preventing Contamination

Contamination is a serious concern when machining polymer components for technically demanding industries such as aerospace and medical sciences. To ensure the highest level of sanitation down to the sub-molecular level, AIP Precision Machining designs, heat-treats, and machines only plastics with any sub-manufactured metalwork processed outside our facility. This allows us to de-risk the process from metallic cross contamination.

 

Polypropylene Machining Guide: Supportive Information

 

ISO 13485:2016 Certification
ISO 9001:2015 Certification

 

Need a machined part from medical grade polypropylene?

Talk to our team of expert engineers and machinists about your project needs and specifications.

 

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How Aluminum Got Dethroned by Thermoplastics in Aerospace

 

Cup holders. Magazines. Suit cases. Aircraft engines. Here’s a riddle, what do these items all have in common? If you’re an aircraft operator, the answer is obvious: they all add weight, making them a drain on your fuel costs.

 

If weight is one of the main operating costs of an aircraft, then it’s no surprise that airlines want to lose a few pounds. Over the last 36 years, AIP has witnessed firsthand the incredible weight savings that can be gained from using lightweight polymers and composites for aerospace applications.

 

How Airlines “Slim Down” Operating Costs

 

How much can an ounce cost you? Plenty. In the case of United Airlines, removing a single ounce from its in-flight magazine has translated to saving $290,000 a year. Yes, a single ounce can hit an airline with up to six digits in costs.

 

If thinner paper can have such an impact on your bottom line, then you can imagine the significant cost savings that can come from manufacturing lighter aerospace components. What’s the most lightweight solution for aircraft operators today? We have one word for you: plastics.

 

What Makes Plastics the Secret to Aircraft Fuel-Efficiency

 

Aluminum was popular during the “Golden Age of Aviation” because of its strength and durability as well as its lightness when compared to other metals like steel. As a result, many aircraft components have traditionally been metal, from aircraft interiors, to landing gear, aircraft engines and structural components.

 

Now consider the fact that polymer and composite materials can be up to ten times lighter than metal. It’s no wonder that as more thermoplastic materials come on the market and new manufacturing opportunities arise, metal replacement has been seen as one of the best opportunities to reduce airline weight.

 

How big is the impact of switching from aluminum to plastic parts like PEEK and ULTEM in aerospace applications? Operators can earn weight savings of up to 60%. This translates to lower lifetime fuel costs, reduced emissions and extended flight range for operators.

 

“Weighing” the Option of Plastics in Aerospace

 

Weight alone is a massive reason to consider thermoplastics for aerospace, but weight isn’t the only factor at play in material selection.

 

After all, wood is lighter than metal, but there’s a reason we don’t build spruce airframes like the first plane from the Wright brothers: it wouldn’t be safe today to fly a wooden plane! Aerospace components need to be able to survive in corrosive, harsh environments as well as provide resistance to high temperatures.

 

In other words, it’s crucial that your mission-critical components aren’t just lightweight, but also high-performing.

 

At AIP, we carefully apply our decades of material expertise to select the right material for your application’s needs. Remember that your aerospace plastics manufacturer should understand the unique demands of your industry and your application, and have experience machining the material you require.

 

Want to learn more about how AIP reduces costs for aircraft operators?

Read how machined polymer components can take a load off aircraft interiors in our aerospace case study.

Download our Case Study

 

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When design engineers need a custom-machined component for a project, many consider metals first for their strength and durability.  However, this is not the case anymore; metals are moving over as polymers and composites become a more sensible alternative for precision-machined, high-strength durable parts.  This is true across many industries, but especially in the aerospace and defense sectors.  In this article, we will explore the benefits of opting for a plastic material for mission-critical aerospace and defense parts.

 

Overall Benefits

 

Machined polymer and composite components are the most cost-effective solution compared to metal.

 

First, machined plastic parts are lighter and, therefore, provide immense advantages over metals by offering lower lifetime freight costs for equipment that is regularly transported or handled over the product’s lifetime. Furthermore, polymers allow lower power motors for moving parts due to lower frictional properties of polymer wear components compared to metals. The low frictional properties preserve the integrity of the part as well, which translates to less maintenance-related downtime. What does this mean for operators?  Equipment remains online longer doing what it’s supposed to do – produce profit and functionality.  Not only are plastics lighter, but they’re also less expensive than many raw metal materials used for parts. Plastics can be produced in faster cycles than metals, which helps keep manufacturing costs down as well.

 

At AIP, we can machine and deliver parts in as little as 10 business days.

 

Explore AIP’s Machining Capabilities

 

Plastics are more resistant to chemicals than their metal counterparts.

 

Without extensive and costly secondary finishes and coatings, metals are easily attacked by many common chemicals. Corrosion due to moisture or even dissimilar metals in close contact is also a major concern with metal components. Polymer and composite materials such as PEEK, Kynar, Teflon, and Polyethylene are impervious to some of the harshest chemicals. This allows for the manufacture and use of precision fluid handling components in the chemical and processing industries.  These parts would otherwise dissolve if they were manufactured from metal materials. Some polymer materials available for machining can withstand temperatures over 700°F (370°C).

 

Plastic parts do not require post-treatment finishing efforts, unlike metal.

 

Polymer and composites are both thermally and electrically insulating. Metallic components require special secondary processing and coating in order to achieve any sort of insulating properties. These secondary processes add cost to metallic components without offering the level of insulation offered by polymer materials. Plastic and composite components are also naturally corrosion resistant and experience no galvanic effects in a dissimilar metal scenario that require sheathing. Additionally, plastic materials are compounded with color before machining, eliminating the need for post-treatment finishing efforts such as painting.

 

Aerospace and Defense benefits graphic
 

 

Benefits to the Aerospace & Defense Sector

 

Polymers bring many advantages to the aerospace and defense industry, particularly in the form of weight-saving capabilities.  Let’s take a closer look at the benefits of precision machined mission-critical components.

 

  • Lightweight: Polymer and composite materials are up to ten times lighter than typical metals. A reduction in the weight of parts can have a huge impact on an aerospace company’s bottom line. For every pound of weight reduced on a plane, the airline can realize up to $15k per year in fuel cost reduction.

 

  • Corrosion-Resistant: Plastic materials handle far better than metals in chemically harsh environments. This increases the lifespan of the aircraft and avoids costly repairs brought about by corroding metal components an in-turn reducing MRO downtime provides for more operational time per aircraft per year.

 

  • Insulating and Radar Absorbent: Polymers are naturally radar-absorbent as well as thermally and electrically insulating.

 

  • Flame & Smoke Resistances: High-performance thermoplastics meet the stringent flame and smoke resistances required for aerospace applications.

 

Aerospace and Defense benefits graphic
 

Other Benefits for Aerospace and Defense

 

  • High Tensile Strength: Several lightweight thermoplastics can match the strength of metals, making them perfect for airplane equipment metal part replacement.

 

  • Flexibility & Impact Resistance: Polymers are resistant to impact damage, making them less prone to denting or cracking the way that metals do.

 

Plastics have a variety of unique attributes which place them above metals in terms of utility, cost-effectiveness and flexibility for precision-machined mission-critical components.  To learn more, search specific plastic materials and their applications per industry with our useful material search function.

 

Download Our Plastics Over Metals Infographic

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PART SUMMARY:

 

One of the high-performance thermoplastics that AIP machines is Polyetherimide (PEI), known by its tradename ULTEM.  Due to its weight-saving properties, high chemical and hydrolysis resistance and tensile strength, ULTEM is popular across several industries: Automotive, aerospace and defense, electrical and electronic market, medical and life sciences and industrial applications and appliances.  Read on to learn about what this incredible polymer can do!

 

MATERIAL PROPERTIES:

 

Polyetherimide (PEI) is an amorphous thermoplastic.  Polyetherimide was developed to provide sufficient flexibility and good melt processability while maintaining excellent mechanical and thermal properties.

 

Key properties of ULTEM PEI include:

  • Handling at temperatures up to 340°F (171°C)
  • Heat Resistance
  • Flame Resistance
  • Chemical Resistance
  • High Rigidity
  • Highest Dielectric Strength
  • Hydrolysis Resistance
  • Low Thermal Conductivity

 

ULTEM Applications

As mentioned previously, ULTEM is a highly sought-after thermoplastic for weight-saving capabilities in aerospace components to reusable autoclave sterilizations in medical applications.  However, it’s most commonly used in high voltage electrical insulation applications.

 

Common uses include:

  • Analytical Instrumentation
  • Dielectric Properties Required
  • Electrical Insulators
  • High Strength Situations
  • Reusable Medical Devices
  • Semiconductor Process Components
  • Structural Components
  • Underwater Connector Bodies

 

So, what can this polymer do?  Let’s take a closer look at how ULTEM (PEI) is applied in the Aerospace & Defense, Medical & Life Sciences and Specialized Industrial markets:

 

WHAT CAN ULTEM DO FOR AEROSPACE & DEFENSE?

 

In the Aerospace & Defense Industry, ULTEM is often applied to aircraft components for weight reduction in place of metal parts.  Additionally, since it has a high thermal resistance rating, polymer components have the benefit of evading radar detection in military aircraft.

 

AIP machines ULTEM 1000 & ULTEM 2300

 

ULTEM 2300 is a 30 percent glass filled version of virgin ULTEM 1000.  The addition of glass increases ULTEM 1000’s dimensional stability by almost three times.

 

For over three decades, AIP has provided flight control, fuel system, interior, engine and aerodynamic-related ULTEM components for various aircraft OEM and MRO providers worldwide.  As this industry continues to expand, evolve and innovate, the demand for high-performance materials like ULTEM contribute significantly to streamlined operations.

 

WHAT CAN ULTEM DO FOR MEDICAL & LIFE SCIENCES?

 

In the Medical Industry, biocompatibility and sterilization are paramount to medical instruments and implants. ULTEM is often a popular choice in this sector due to its resistance to chemicals and lipids.  Polyetherimide also withstands dry heat sterilization at 356°F (180°C), ethylene oxide gas, gamma radiation and steam autoclave.

 

Some popular medical applications include disposable and re-usable medical devices and medical monitor probe housings.  These could be surgical instrument handles and enclosures or non-implant prostheses.  It gets extensive use in membrane applications due to its separation, permeance and biocompatible properties.

 

WHAT CAN ULTEM DO FOR SPECIALIZED INDUSTRIAL Sectors?

 

At AIP, we precision machine ULTEM for many specialized industrial applications as well: automotive, electrical and metal replacement, to name a few.  Despite the diversity of these industrial applications, we have the inventory and machining capabilities to provide solutions for any project specifications.

 

PEI is most often used in electrical and lighting systems in the automotive market for its high heat resistance, mechanical integrity and strength.  Principal automotive applications include: transmission parts, throttle bodies, ignition components, thermostat housings, bezels, reflectors, lamp sockets and electromechanical systems.

 

The electrical and electronic markets demand high heat resistant materials.  ULTEM is an excellent choice for applications such as electrical circuit boards, switches, connectors, electronic chips and capacitors.

 

As discussed previously, thermoplastics like ULTEM often replace metal parts in industrial applications.  For this reason, it’s often used in housewares, especially fluid handling systems.  Some of these applications are: HVAC equipment, microwave cookware, steam and curling irons, dual-ovenable trays for food packaging that meets FDA food packaging requirements.

 

What can AIP Precision Machining do for you?

 

From concept to completion, our team of engineers will work with you to realize the final product.  With some of the fastest lead times in the industry, our unrivaled technical experts we can tackle your polymer challenges.

 

What Can This Polymer Do? Supportive Information

 

Medical Sector Biomaterials Guide

Energy Sector Materials Guide

Aerospace Sector Materials Guide

Amorphous Materials

Aerospace Case Study: Weight-saving Polymers

 

 

CUSTOMIZED FOR YOUR APPLICATION

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An Informational Brief on Polymer Machining

 

Machining High Density PolyethyleneAmong the many polymer materials we machine at AIP, High Density Polyethylene (HDPE) is a common material choice for commercial polymer applications.  HDPE is part of the Polyethylene (PE) family of thermoplastic polymers with variable crystalline structure.

 

First developed in the 1950s by German and Italian scientists Karl Ziegler and Giulio Natta, PE has become one of the most widely produced plastics in the world.  Polyethylene comes in several compounds each with various applications: Low Density Polyethylene (LDPE), High Density Polyethylene (HDPE) and Ultrahigh Molecular Weight Polyethylene (UHMW) are some of the most well-known.

 

For example, you will find LDPE most likely in the grocery store as plastic wrap or grocery bags.  In contrast, HDPE, due to its high density, is much better suited for construction components like a drain pipe.  And UHMW can be machined into high performance applications for medical devices, bulletproof vests and industrial wear components.

 

In this machining guide, we will discuss what goes into machining HDPE and how its considerations differ from other manufacturing options such as metal machining, injection molding, and 3D printing.

 

A Brief History of Plastic CNC Machining

 

How does AIP approach HDPE and its machining process? To start, let’s explore what plastic machining is, specifically CNC machining.

 

CNC (Computer Numerical Control) machining is a process in the manufacturing sector that involves the use of computers to control machine tools. In the case of plastic machining, this involves the precise removal of layers from a plastic sheet, rod, tube or near net molded blank.

 

Shortly after World War II, the earliest version of CNC technology was developed as a dependable, repeatable way to manufacture more accurate and complex parts for the aircraft industry.  John Parsons is credited with developing numerical control – a method of producing integrally stiffened aircraft skins.

 

While working at the family-owned, Michigan-based business – Parsons Corp., John collaborated on the development of a system for producing helicopter rotor blade templates.  Using an IBM 602A multiplier to calculate airfoil coordinates, and inputting this data to a Swiss jig borer, it was possible to produce templates from data on punched cards.

 

In 1949 Parson’s templates were applied to Air Force research projects at MIT.  Following extensive research and development, an experimental milling machine was constructed at MIT’s Servomechanisms Laboratory.

 

Machining polymers and composites is a precise science that requires strong technical expertise.  For instance, some plastics are brittle, while others melt at a specific temperature.  These diverse mechanical and thermal properties result in varying behaviors when CNC machined.  Thus, it is imperative to understand the polymer structure and qualities of HDPE if you’re machining it.

 

Ever wonder about the differences in cost and process among 3D Printing, Injection Molding or Plastic Machining?

 

Check out our blog:
“Settling the Debate”

 

 

Properties of HDPE

 

HDPE is a high impact, high density crystalline thermoplastic.  It also has a low moisture absorption rate and good chemical and corrosion resistance.  Compared to its sister polymer LDPE, HDPE offers much greater impact resistance and tensile strength.  This polymer has a melt temperature of 266 F (130 C).  Its tensile strength is 20 MPa (2,900 PSI); to put this number into perspective, a slab of concrete may be able to withstand 3,000 PSI.

 

Oftentimes, people use HDPE in everyday home appliances and commercial containers.  Due to its strength and corrosion resistance, it’s a common candidate for garbage bins, laundry detergent cartons and cutting boards.  It is also safe to use for food contact such as milk cartons.

 

PE is available in sheet stock, rods, and even specialty shapes in a multitude of variants (LDPE, HDPE etc.), making it a good candidate for subtractive machining processes on a mill or lathe. However, colors are usually limited to white and black.

 

Machining HDPE

 

Annealing HDPE

Annealing greatly reduces the chance that surface cracks and deformation due to internal stresses will occur from the heat generated during machining HDPE. AIP uses computer controlled annealing ovens for the highest quality precision machining of all thermoplastics.  Talk to our engineers about any questions you have about the annealing of a specific polymer.

 

Machining HDPE

As a crystalline thermoplastic, HDPE can be machined at tight tolerances; remember dimensional stability and strength!  AIP recommends non-aromatic, water-soluble coolants because they are most suitable for ideal surface finishes and close tolerances. Keep in mind however that HDPE has a very low CTLE and therefore will move quite a bit with slight temperature changes.  Some examples are pressurized air and spray mists. Coolants have the additional benefit of extending tool life as well.

 

Some companies machine both metals and plastics, which has detrimental outcomes for clients. Many past experiences have shown parts going to customer without cracks, only to develop cracks over time due to exposure to metal machine shop fluids. Be sure to use a facility like AIP that only machines polymers.

 

Preventing Contamination

 

Contamination is a serious concern when machining polymer components for technically demanding industries such as aerospace sciences. To ensure the highest level of sanitation down to the sub-molecular level, AIP Precision Machining designs, heat-treats, and machines only plastics with any sub-manufactured metalwork processed outside our facility.  This allows us to de-risk the process from metallic cross contamination.

 

HDPE (High Density Polyethylene) Machining Guide: Supportive Information

 

Miscellaneous Materials Guide

ISO 13485:2016 Certification

ISO 9001:2015 Certification

Learn more about HDPE and its applications in other industries

 

Discover what HDPE can do

 

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Learn about the re-useable capabilities of precision plastics

 

In the world of recycling, plastic tends to have a bad reputation or it gets whispered like a dirty word.  Indeed, according to the UN Environment Programm, one million plastic drinking bottles are purchased every minute.  This is certainly a disturbing statistic, and we are tasked with addressing the consequences of this waste.  However, it is important to distinguish the type of plastics causing severe pollution.  Plastic bottles and plastic bags are single-use, disposable plastics.  These are the ones that are clogging up the environment.

 

What people don’t discuss often is plastics that are re-usable and recyclable.  At AIP, the plastics that we precision machine are high grade, quality polymers made for durability and continuous use in the following industries: Aerospace and Defense; Medical and Life Sciences; Power and Energy; Specialized Industrial.  That means they are evergreen materials that will not only last, but could be repurposed for a different application altogether.  Read on to find out about some of the high-performance polymers we work with, what they are used for and how they can be recycled.

 

Everyday Sustainable Precision Plastics
Polymer Properties AIP’s Machined Applications
PPS Broadest chemical resistance; zero moisture absorption; dimensional stability; ultra-low wear factors and structural strength

*available in several grades

Case Study: High-quality PPS wheel bushings for a theme park water ride.

  • Reduced ride downtime
  • Saved on maintenance and inventory costs
  • Lower energy cost
  • Efficient design
  • Low-wear
TORLON Highest performing, melt-processible plastic; maintains strength and stiffness up to 500 F; chemical, thermal and stress resistance

*available in several grades

Ideal for critical mechanical and structural components for severe levels of temperature and stress

  • Jet Engine Components
  • High Temperature Electrical Connectors
  • Automotive Transmission components
  • Wear Rings in Oil Recovery
  • Valve Seats
PEEK Biocompatible; abrasion and chemical resistant; low moisture absorption; very low smoke and toxic gas emission

*available in several grades

Case Study: PEEK Dynamic Telescopic Craniotomy (skull plate for brain traumas

  • Reduced ride downtime
  • Saved on maintenance and inventory costs
  • Lower energy cost
  • Efficient design
  • Low-wear
RADEL Impact resistance; hydrolytic stability; excellent toughness; chemical resistance; heat deflection temperature of 405 F (207 C)
ULTEM Excellent heat and flame resistance; high rigidity and strength; low thermal conductivity; highest dielectric strength

*available in several grades

Used as structural components in several industries

  • High-voltage circuit-breaker housings
  • High-temperature bobbins, coils, fuse blocks and wire coatings
  • Jet-engine components
  • Aircraft interior and electrical hardware parts
  • Microwave applications
  • Replaces glass in medical lamps

 

Thermoplastics – The Green Plastic

 

There are two types of polymers – thermoplastics and thermosets.  The plastics that we work with primarily at AIP are thermoplastics.  So, what’s a thermoplastic and how is it re-usable or recyclable?

 

It’s all about how the polymer reacts to chemicals and temperature.  Thermoplastics soften when heated and become more fluid, which makes them a very flexible polymer.  For this reason, these plastics can be remolded and recycled without losing their mechanical properties or dimensional stability.  Let’s go in depth on some of the common thermoplastics we use for evergreen applications.

 

The AIP case study focusing on the use of PPS for the log flume ride bushing component is an excellent example of a thermoplastic built and machined for continuous use.  The bushing made from PPS could be used over and over again without wear.  Furthermore, it could be immersed in water and other chemicals without losing dimensionality or durability.

 

PEEK and ULTEM are both common polymers we machine at AIP.  With PEEK’s high chemical resistance and biocompatibility, it is ideal for surgical applications such as the Dynamic Telescopic Craniotomy Case Study.  This polymer can withstand the internal temperatures and fluids of the body for extended use.

 

ULTEM is known for its strength and rigidity in extreme environments and temperatures.  This polymer is often used for re-useable medical instruments, since it reacts well to autoclave sterilizations.  Additionally, it’s flammability rating and dimensional stability make it ideal as a weight-saving aerospace component.

 

As the plastics industry continues to innovate, the next generation of research will turn towards more sustainable and environmentally conscious materials.  Thermoplastics are one of the pioneers of this industry – leading plastics into the future as a material that can be reused and recycled.

 

Unrivaled Expertise. Unparalleled Results

 

Helicopter landing on shipWith 36+ years of experience in the industry, our dedicated craftsmen and ties to leading plastic manufacturers allow us to provide you with unrivaled knowledge and consulting in material selection, sizing, manufacturing techniques and beyond to best meet your project needs.

 

AIP offers a unique combination of CNC machining, raw material distribution, and consultancy as a reliable source for engineering information for materials such as PEEK, TORLON, ULTEM and more.

 

We are AS 9100D compliant; certified and registered with ISO 13485 and ISO 9001 and standards in our commitment to machining quality custom plastic components for specialized industrial sectors. Quality assurance is included as an integral part of our process and is addressed at every step of your project, from concept to completion.  Unrivaled Expertise.  Unparalleled Results.

 

 

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PART SUMMARY:

 

PEEK (PolyEtherEtherKetone) is a lightweight highly chemical resistant thermoplastic popular in the Aerospace & Defense and Medical & Life Sciences Industries.  From implants to custom medical devices or machined lightweight aircraft components, PEEK is ideal for a variety of specialized applications.

 

MATERIAL PROPERTIES:

 

PEEK is considered a semi-crystalline, high-performance thermoplastic. This gives it enough elasticity to be precision machined to various custom designs, with strong mechanical properties that provide resistance to fatigue and stress-cracking, as well as a good structure for bearing, wear and structural applications.

 

Key properties of PEEK include:

  • Handling at temperatures up to 480°F (250°C)
  • Abrasion Resistance
  • Chemical Resistance
  • High Ductility
  • High Elongation
  • Hydrolysis Resistance
  • Low Outgassing

 

What can this polymer do?

 

Due to its elasticity and resistance to chemicals, abrasion and hydrolysis, PEEK is a highly sought-after thermoplastic for both industrial-grade and medical-grade applications.

 

Common uses include:

  • Aerospace Weight Reduction Components
  • Dental Implants
  • Food and Beverage Automated Manufacturing Equipment
  • Food and Beverage Filling
  • Medical Implants
  • Medical Instruments
  • Metal Replacement
  • Processing Equipment
  • Semiconductor Manufacturing Equipment
  • Vacuum Chamber Applications

 

So, what can this polymer do?  Let’s take a closer look at how it is applied in the Aerospace & Defense and Medical & Life Sciences industries:

 

AEROSPACE & DEFENSE

 

In 1978, ICI invented PEEK, a member Of the PAEK (polyaryletherketone) family of thermoplastic polymers.  It quickly gained recognition in the aerospace and defense industry for its weight-saving capabilities over metal alloys.  For example, Airbus used PEEK for a primary structural component in the door of the A350 XWB to improve quality and reduce weight and costs by 40 percent.  Over the next 15 years, industry professionals forecast that 41,000 new and replacement planes will be required.  Officials and engineers in the aerospace industry are looking for alternative high-performance thermoplastics like PEEK to meet this material demand.

 

Read more on PEEK’s impact in the aerospace and defense industry in our downloadable booklet below

 

As demand for stream-lined, innovative materials grows, we continue to serve and precision machine complex polymers for the aerospace and defense industries. For over three decades, we have provided flight control, fuel system, interior, engine and aerodynamic-related PEEK components for various aircraft OEM and MRO providers worldwide.

 

MEDICAL & LIFE SCIENCES

 

PEEK gained traction in the medical industry 20 years after the aerospace industry adopted it. In the late 1990s, Invibio Biomaterial Solutions commercialized a bio-compatible grade of PEEK (PEEK-OPTIMA). Ever since then, demand for medical grade PEEK devices has skyrocketed. From surgical instruments to spinal fusion implants, PEEK has a wide range of applications that only continues to expand in the medical industry.

 

Peek Neurosurgical Case Study

 

One such example of PEEK’s versatility is in neurosurgery for stroke and traumatic brain injuries.  Dr. Rohit Khanna partnered with AIP Precision Machining engineers to create a device that would expand without another operation, yet hold the “bone flap” and the rest of the skull together.

 

Problem

Dr. Rohit Khanna wanted to develop a device that would relieve swelling in the skull for patients undergoing brain surgery, which can lead to complications or even death.

 

Solution

The polymer of choice?  PEEK.  AIP’s engineers machined a medical component that was flexible, strong and sensitive enough to fulfill the necessary requirements for this critical medical part.  PEEK was also the best choice for this medical application because it was the most ductile and biocompatible.

 

medical tool built with peek polymer
 

Resolution

Currently, the FDA is processing the PEEK surgical piece for clearance to conduct clinical trials.  If it is approved to move forward, it can make leaps and bounds in reducing the need for multiple brain surgeries, saving more lives.

 

Get the full case study on PEEK

 

What can this polymer do?

From concept to completion, our team of engineers will work with you to realize the final product.  With some of the fastest lead times in the industry, our unrivaled technical experts we can tackle your polymer challenges.

 

What Can This Polymer Do? Supportive Information

PEEK VARIANTS

 

Download our “What Can This Polymer Do?” booklet.

We’ve put together our premier PEEK applications in a condensed booklet you can take with you.

Learn here.

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Where Does This Part Go?

PPS Wheel Bushing | AIP Precision Machining

 

If you’ve been to a popular Florida amusement park, then it’s possible you’ve encountered the latest part starring in our “Where Does This Part Go?” series.

Find out why this part really makes a “splash” in the section below…

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Thermoplastics in Medical ApplicationsWhen it comes to choosing a thermoplastic material for your medical applications, product durability, agency approval, biocompatibility and cleanliness aren’t just desirable—they’re essential. Beyond even that, though, a host of other factors must be considered when determining which high-performance plastic or composite material to use for an implant, orthopedic surgical guides, body fluid contact components, spinal devices, or surgical instruments. Medical product applications are becoming more and more advanced due to critical performance and alignment requirements as well as the need for radiolucency to support minimally invasive procedures. Therefore, the choice of plastic material specified for a given application as well as a manufacturer with battle-hardened experience is the critical first step in your decision process.

 

AIP has well over three decades of expertise with thermoplastic materials, and understands how plastics react when machined. We are one of a very select few companies able to hold incredibly tight tolerances in plastic parts. AIP has been successfully audited by some of the most stringent OEMs in the orthopedic and medical device industries, and are ISO 13485:2016, ISO 9001:2015 and FDA registered.

 

Here are just a few initial, yet critical considerations that take place when we determine the thermoplastic to best suit your particular medical or life science application.

 

Biocompatibility

 

If your components are going to come into contact with body tissue or fluids, then those components must be biocompatible per ISO 10993; if the manufacturer you are working with is not familiar with this standard and cannot provide you with this certification for the material, then move on to a manufacturer with medical industry knowledge. This is especially true if the polymers will undergo long-term contact with body tissues and fluid, such as when used as an implant. Polymers can undergo degradation due to biochemical and mechanical factors in the body, which results in ionic attack and formation of hydroxyl ions and dissolved oxygen. In turn, this can lead to tissue irritation, inflammation, and other reactions with body-like corrosion, wear and potential death. Due to this, very few polymers are available as medical grade for medical application, with an even smaller amount considered a candidate for implants.

 

AIP Precision Machining includes machined PEEK implants among its many capabilities for custom medical applications precisely due to PEEK’s biocompatibility. PEEK is also inert to body fluids, making it exceptional for bone surgery as well as areas of traumatology and orthopaedics. Another valuable trait of PEEK is that this material has a very similar modulus to that of human bone. The similar modulus to bone reduces the potential for stress shielding. Stress shielding is common with metallic implants whereby the metal implant and bone do not become one nor work in unison to form a single construct. By using Invibio’s PEEK Optima or Solvay’s Zeniva PEEK as an implant material, the bone and PEEK will grow into a single construct mimicking the bone’s natural tendency to repair the fracture or fusion.

 

Sterilization Compatibility

 

Plastics react differently to various sterilization methods, and if a product is not a single-use device and involves body tissue and fluid contact, then it may regularly undergo sterilization. The usual sterilization methods are radiation (gamma/e-beam), chemical (ETO), or autoclave (steam). ETO is rarely a concern, but radiation and autoclaving both require resistance from plastics. Several radiation resistant thermoplastics are:

 

 

When it comes to autoclaving, the best polymers for resistance are PPSU and PEEK, with both capable of handling exposure to thousands of cycles.

 

AIP takes the matter of sterilization seriously and ensures the highest level of sanitation down to the sub-molecular level for its products. By designing, stress relieving and machining only plastics, AIP significantly reduces the threat of metallic cross-contamination and therefore allows for the highest hygienic products possible.

 

Chemical Resistance

 

A polymer can be exposed to plenty of disinfection chemicals in a hospital. That exposure can deteriorate plastics, and negatively affect part performance. Polymer chains can be affected by isopropyl alcohol, bleaches, and peroxides. Semi-crystalline polymers like PP, PE, PTFE and PEEK can be expected to have better chemical resistance than amorphous polymers like ABS and PC. However, it’s important to check the performance to be certain of resistances, as exceptions can take place.

 

With decades of experience working with thermoplastics, AIP guarantees extreme chemical resistance in its material selection for your medical applications.

 

Electrical & Thermal Properties

 

Dielectric strength and thermal resistance are necessary for medical devices enclosed in areas that require high heat resistance. Thermoplastics such as PC (Polycarbonate), PC blends, PPS (polyphenylene sulfide), PEI and PS (polystyrene) blends have electrical properties that perform well, some even at elevated temperatures.

 

AIP’s material library includes thermoplastics that exhibit extreme thermal performance, and we are familiar with machining them in applications for medical life & sciences.

 

Mechanical Properties

 

Properties such as tensile and compressive strength, wear resistance, impact strength, and bending stiffness also must be considered when choosing your thermoplastic. Engineered thermoplastics such as PC, PEEK, PPSU, POM, PEI and reinforced grades of these same materials (glass, aramid and carbon fillers) perform very well in this respect, making them ideal for a variety of climate conditions, such as during transportation.

 

AIP provides thermoplastics that show extreme wear resistance, x-ray visibility or invisibility and high structural performance.

 

These are just a few of the many considerations that take place when choosing the right plastic for your medical applications. AIP offers you our full material consultancy from concept to completion, so that together, we find the right thermoplastic for your projects.

 

 

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Thermosets vs Thermoplastics

Your Brief Guide to Polymer Materials

 

When it comes to polymers, you have two basic types: thermoplastics and thermosets. When machining plastic, it’s crucial to know which one you’re working with due to distinct differences between how these two main polymer categories react to chemicals and temperature.

 

Thermoplastics soften when heated and become more fluid as additional heat is applied. The curing process is completely reversible as no chemical bonding takes place. This characteristic allows thermoplastics to be remolded and recycled without negatively affecting the material’s physical properties. 

 

Thermoplastics possess the following properties:

  • • Good Resistance to Creep
  • • Soluble in Certain Solvents
  • • Swell in Presence of Certain Solvents
  • • Allows for Plastic Deformation when Heated

 

Thermosets contain polymers that cross-link together during the curing process to form an irreversible chemical bond. The cross-linking process eliminates the risk of the product re-melting when heat is applied, making thermosets ideal for high-heat applications such as electronics and appliances.

 

Thermosets possess the following properties:

  • • High Resistance to Creep
  • • Cannot Melt
  • • Insoluble
  • • Rarely Swell in Presence of Solvents

 

Phenolic, Bakelite, Vinyl Ester and Epoxy materials would be considered examples of a thermoset, while ULTEM, PEEK, TORLON and Polycarbonate materials are examples of thermoplastics.

 

The thermoplastic category of polymers is further categorized into Amorphous and Crystalline polymers per the figure below:

 

 

Most amorphous polymers are thermoform capable, translucent and easily bonded with adhesives or solvents. One example of this would be TORLON.

 

Semi-crystalline polymers are difficult to bond or thermoform, but possess better chemical resistances, electrical properties and a low coefficient of fiction. An example of a semi-crystalline polymer would be PEEK.

 

Want to learn more about AIP’s polymer and composite materials?

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