PEEK Medical Injection Molded Parts

Features: high temperature resistance, self-lubrication, chemical resistance, flame retardancy, hydrolysis resistance, wear resistance and fatigue resistance and other excellent properties. The main products of Zhongwei Precision Machinery Co., Ltd. are nylon products, plastic products, ABS series, rubber products, etc. Types of injection molding materials that can be processed: polyethylene (PE), polypropylene (PP), nylon (PA, PA6, PA66), polyoxymethylene (POM), ABS, polyurethane (TPU), polyphenylene sulfide (PPS), polystyrene Carbonate (PC), Polyetheretherketone (PEEK), etc.

Product Description

1. Implementation standards: the company strictly implements ISO9001, ISO14001, IATF16949, VDA6.3 certification, and products have passed ROHS, FDA EU certification, etc.

2. Product material standards: ISO, GB, ASTM, SAE, EN, DIN, BS, AMS, JIS, ASME, DMS, TOCT, GB

3. Main processes: plastic injection molding, metal insert injection molding, investment casting, die-casting aluminum

4. Available materials for injection molding:

Processable nylon products, plastic products, ABS series; injection molding material types: polyethylene (PE), polypropylene (PP), nylon (PA, PA6, PA66), polyoxymethylene (POM), ABS, polyurethane (TPU), poly Phenyl sulfide (PPS), polycarbonate (PC), polyether ether ketone (PEEK) and 3D printing can be customized according to customer requirements.

Production Process

Polyaryletherketone, referred to as PAEK, is a type of crystalline aromatic thermoplastic polymer in which phenylene rings are connected by ether bonds and carbonyl groups (ketone groups). According to the connection order and ratio of ether bond, ketone group and benzene ring in the molecular chain, many different polymers can be formed, such as polyether ketone PEK, polyether ether ketone PEEK, polyether ketone ketone PEKK, polyether ether ketone ketone PEEKK and polyetherketone ether ketone ketone PEKEKK and other varieties. Among them, polyetheretherketone PEEK is the first industrially produced variety. Polyetheretherketone (hereinafter referred to as PEEK) was successfully researched and developed by British Imperial Chemical Industries (IC) in 1978. PEEK Medical Injection Molded Parts has high-grade heat resistance, corrosion resistance, radiation resistance, and excellent performance. Fatigue resistance and electrical properties, as well as excellent processability and many other advantages, have become recognized as one of the world's highest performance thermoplastic materials. It was originally used in the field of defense and military industries, and then gradually expanded to civilian fields, including industrial manufacturing, aerospace Aerospace, automotive industry, electrical and electronic and medical equipment, etc.

1. History of PEEK

1960s: In 1962, the American Dupont Company and the British ICI Company in 1964 reported the synthesis of polyaryletherketone by electrophilic substitution in the presence of Friedel-Crafts catalyst. 1993-2005: In 1993, ICI's PEEK was acquired by Victrex. In 1999, Victrex's production capacity increased to 2,000t/a, and in 2005, it expanded again to 2,800t/a. At the same time, Viagra actively developed civilian high-tech products. For applications in the field of science and technology, the market size continues to grow at a rate of about 15% every year. 1978-1992: ICI successfully developed PEEK in 1978 and started commercialization. 1000t/a production plant was started in 1987. Before 1993, PEEK was mainly used in the western military industry, and the market size was only 400t/a. 2000-2005: China began to study polyetheretherketone as a national key project from the "Seventh Five-Year Plan". Jilin University established Changchun Jida High-tech Materials Company in 2000 to develop and produce PES and PEEK resins on a large scale. At the end of 2003, a 500t/year production line was built and put into operation. In 2005, the German company Evonik invested capital to establish Jida Evonik High Performance Polymer Co., Ltd. Jilin University holds 20% of the shares and Evonik holds 80% of the shares. 2006: Solvay acquired the polymer division of Gharda Chemical Company in India at the end of 2006, and established the first PEEK commercialization unit in India in 2008, with an annual production capacity of 500t. 2009-2012: Victrex built a new plant with a scale of 1450t/a in 2009, with a total production capacity of 4250t/a. Since then, the production capacity has continued to expand. By 2012, the production capacity of Victrex's new plant has reached 7150t/a, accounting for 60% of the total global production capacity. 2012-2014: In 2012, Solvay expanded the production of PEEK and PAEK (polyaryletherketone) polymers in the Indian production base, and the production capacity reached 1500t/a in 2013. At the same time, Savli in India set up another An important R&D center. In May 2014 Solvay SA introduced a new high stiffness grade KetaSpire polyetheretherketone (PEEK), KetaSpire KT-825, which has a modulus/stiffness 50% higher than standard pure PEEK grades 2015:2015 Jida Evonik High Performance Polymers will expand its production capacity to 1250t/a. to meet growing global demand. The products are mainly exported to Europe, Italy and other countries, and there are few products in the Chinese market. 2018.9: Victrex partnered with the University of Exeter (UK) to launch a new generation of PAEK polymers and composites for 3D printing in the aerospace industry. This partnership facilitates the broader development of 3D printing technology by both parties. 2018.11: Evonik Industries AG developed the world's first implantable PEEK filament for 3D printing applications. This high-performance material can be used in fuse fabrication (FFF) technology. 2019.3: Evonik Industries AG launches new radiopaque PEEK material for implant technology in healthcare applications. Evonik developed PEEK containing barium sulfate. This product type facilitates radiographic contrast without the formation of artifacts as it can be viewed with other materials for implantation techniques. 2019.3: Arkema opens its first PEKK production plant in the US.

2. Polyetheretherketone-physical properties

(1) Basic physical properties

Polyetheretherketone PEEK is a semi-crystalline aromatic thermoplastic engineering plastic. Therefore, it has three typical thermal transition temperatures: the glass transition temperature (Ta) is 143°C, the crystallization temperature (Tc) is 285°C, and the melting point (Tm) is 334°C. It has a density of 1.265g/cm3 in the amorphous state and 1.32g/cm3 at maximum crystallinity.

Note: Figure A: Molecular structure of PEEK Figure B: Orthogonal unit cell of PEEK

(2) Molecular structure and crystallinity From the structural formula of PEEK, it can be seen that it has an aromatic molecular skeleton, and there are ketone groups and ether groups between the aromatic ring groups. There are a lot of benzene rings in the molecule, so it will have a good Heat resistance and mechanical properties. It can be seen from the crystal structure that PEEK is a two-phase semi-crystalline polymer composed of amorphous phase and crystalline phase. Generally, the crystalline content of products is 20~35%. According to the processing technology, a wider range of crystallinity (0~40%) can be obtained

(3) High temperature resistance/thermal stability PEEK is a high temperature resistant thermoplastic, and its crystalline form makes it have outstanding heat resistance and mechanical properties. It has a melting temperature of 340°C, and thermal degradation and volatile generation are hardly measurable below 427°C.

At 250°C, a decrease in mechanical properties was only detected after 16 weeks. At 310 ℃, its mechanical properties decreased rapidly. It shows that it can be used for a long time at a higher temperature. Compared with other high temperature resistant materials such as polyimide (PI, polyphenylene sulfide (PPS), polytetrafluoroethylene (PTFE), polyphenylene ether (PPO), etc., the use temperature The upper limit is nearly 50 °C higher, and the instantaneous use temperature can reach 300 °C, and it will not decompose for a short time at 400 °C.

ItemPEEKPTFEPPOPI Tensile Strength/MPA972066116 Tensile Elastic Modulus/GPA2.80.42.7-Bending Strength/MPA14213110176 Bending Elastic Modulus/GPA3.7-2.03.3 Compressive Strength/MPA13012100148 Charpy Notched Impact Strength/KJm4.440.160. 090.10 Coefficient of linear expansion 4.8115.64.0 Thermal deformation temperature/C° (1.82MPA) 15255190.

(4) Chemical stability

PEEK-OPTIMA and CF-PEEK-OPTIMA compounds and composites have undergone extensive biocompatibility testing to meet the standards of their FDA Master File. These tests included numerous studies of systemic, intradermal toxicity, and intramuscular implants, none of which showed adverse side effects. PEEK is non-sensitizing and non-genotoxic according to ISO 10993-10-1995.

(6) Excellent mechanical properties

●Bending strength: PEEK can maintain high strength at high temperature. Its bending strength at 200℃ is about 24MPa, which is higher than that of PTFE at room temperature. At 250℃, the bending strength and compressive strength are still 12~ 13Mpa.

●Rigidity: PEEK has higher rigidity, better dimensional stability, and lower coefficient of linear expansion, which is very close to that of metal aluminum.

●Fatigue resistance: good toughness, excellent fatigue resistance to alternating stress is the most outstanding of all plastics, comparable to alloy materials.

●Wear resistance: It has outstanding tribological properties, excellent sliding wear resistance and fretting wear performance, especially at 250℃, it can maintain high wear resistance and low wear coefficient.

●Processability: easy extrusion and injection molding, excellent processability and high molding efficiency.

3. Production process

4. There are two types of process routes for PEEK synthesis: nucleophilic routes and circuit-friendly routes

●Nucleophilic route

With difluorobenzophenone and hydroquinone in the presence of anhydrous sodium carbonate, with diphenyl sulfone as a solvent, that is, in an aprotic polar solvent, at 280 ° C ~ 340 ° C, carry out a polycondensation reaction to obtain high molecular weight. Polyetheretherketone has the advantage that side reactions such as branching and crosslinking of the polymer are easier to control. However, the reaction conditions are harsh, the synthesis industry is complex, the monomers are expensive, and the cost is high, which is also the high price of PEEK and restricts its application. a major reason.

●Pro Circuit Wires

The process adopts low temperature reaction with diphenyl ether and isophthaloyl chloride as raw materials. Its advantages are mild conditions and convenient source of raw materials, but there are side reactions such as polymer branching and cross-linking. Therefore, for the synthesis of electrophilic lines, how to effectively control side reactions such as polymer chain branching and cross-linking to obtain high molecular weight polymers, the selection of reaction solvents is particularly important.

At present, the first type of nucleophilic process is mainly obtained in industrial production.

Post Injection Molding Process

1. Processing equipment: CNC, WEDM, lathe, milling machine, drilling machine, grinder, etc.;

2. Surface treatment: For some products that require subsequent processing, we can provide surface treatment services to achieve the special purpose of customers. At present, we can provide degreasing, polishing, electroplating (gold, silver, nickel, tin, galvanized, etc.), anodizing, electrophoresis and other surface treatment services for precision parts.

Moulds and Inspection Fixtures

1. Mold service life: usually semi-permanent. (except for lost foam)

2. Mold delivery time: 10-25 days, (according to product structure and product size).

3. Tooling and mold maintenance: Zhongwei is responsible for precision parts.

Quality Control

1. Quality control: the defective rate is less than 0.1%.

2. Samples and trial run will be 100% inspected during production and before shipment, sample inspection for mass production according to ISDO standards or customer requirements

3. Testing equipment: automated visual inspection equipment can carry out 100% inspection of products, spectrum analyzer, golden elephant analyzer, three-coordinate measuring machine, hardness testing equipment, tensile testing machine.