Performance Plastics specializes in precision injection molding of high-performance plastics. Our precise production process gives us the ability to injection mold difficult polymers, producing high quality thermoplastic products.

High performance plastic materials, such as PAI (Polyamidimide) Torlon®, have ideal properties when it comes to strength and durability. Recognized as being one of the highest performing thermoplastic materials, Torlon® exhibits greater compressive strength and impact resistance than other high-performance plastic. Torlon’s high creep resistance and extremely low coefficient of linear thermal expansion (CLTE) provides excellent thermal stability. Creating manufactured parts that exhibit high levels of tensile strength, friction wear, compression strength, and rigidity, ensuring exceptional mechanical loading capabilities up to 525°F (275°C).

At Performance Plastics, we are experts in injection molding, specializing in high performance plastics. High performance plastics, such as Torlon®, can be extremely difficult to injection mold due to the polymers unique structure. Torlon® is a reactive polymer, which can cause complications during the injection molding process. A specific set of conditions, equipment, and processing procedures must be followed to effectively injection mold Torlon®. Our proprietary tool design software, processes and equipment enables us to injection mold components having complex geometries made from challenging ultra, high-performance thermoplastic materials and reinforced compounds. We utilize a unique combination of extensive material knowledge, mold flow analysis, a design system and process expertise to eliminate or minimize the need for secondary operations. Our expertise in process control allows us to effectively injection mold Torlon® in parts with extremely tight tolerances. Giving us the ability to provide you an injection molded part made from the highest strength and stiffness of any commercial thermoplastic.

 

 

 

Having a mold made is a large investment for any size company. Running between $30,000 to $70,000, molds are an investment that need to be reliable the first time, all the time.

But it seems more and more, Performance Plastics is seeing customers looking to transfer their molds because those molds can’t achieve company goals. This blog explores our history of transferring molds made by others to us and how our processing expertise pays off for customers in the long run.

Why Transfer?

“One of our customers has a mold that makes 1 million parts per year for a critical application, but they weren’t getting consistent production from their previous supplier,” says Chris Lawson, chief operating officer at Performance Plastics. “They were worried about the inconsistency of their supply and if that would translate into failure in the field.”

The main reason for transferring a mold from one supplier to another comes down to the supplier’s expertise in using the mold. Generally, the customer isn’t seeing consistency in the parts coming out of the mold and knows that something is missing in the strategy – but they’re not sure what.

“At least half of the customers we currently have started out by transferring their mold to us,” Lawson says.

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The Handoff

Like so many others, that million-part customer reached out to Performance Plastics to discuss mold transfer. But the process doesn’t begin with packing the mold into a crate and shipping it to our Cincinnati offices. It starts with defining the problem.

“Does the customer understand why they’re not getting the type of product they need, and do they understand what they perceive the product to be?” Lawson asks. “We spend time with the customer trying to understand what the product should do; what does the customer believe is critical.”

For example, a customer might need “Diameter A” to be perfect. However, production of the mold was driven more by some other product feature.

“We have to understand what’s important to them and why they aren’t getting it out of the product,” Lawson says. “We try to define the problem, where most can only identify the symptoms.”

Once the problem is defined and the mold is transferred, Performance Plastics gets to work … and that starts with running the mold as though it came in new.

“We just want to see what happens with it,” Lawson says. “Sometimes the previous supplier just didn’t follow a robust approach in working with the mold and missed something. We can identify that.”

Performance Plastics uses everything from basic scientific injection molding principles to design of experiment (DOE) concepts. DOE is a branch of applied statistics that deals with planning, conducting, analyzing, and interpreting controlled tests to evaluate the factors that control the value of a parameter or group of parameters. It is a powerful data collection and analysis tool that can be used in a variety of experimental situations.

“Most people don’t understand DOE when they are testing something,” Lawson says. “You’re trying to understand how five different factors interrelate to results that you believe are important, and that’s where we specialize.”

The Transfer Process

Transferring a mold from one supplier to another can take between two and six weeks – although Performance Plastics has done it in as little as three days!

“Once we get our process engineers involved, we can move rather quickly,” Lawson says. “It just depends on if any changes need to be made to the mold itself.”

Performance Plastics has three toolmakers in house that can handle mold modifications to correct errors, and to create fixtures and robotic end effectors if needed.

A lot of the timing revolves around the customer’s ability to supply their own customers. Because the mold is already in use and contracts have been signed, customers need to keep up their inventory of parts to meet demand, all while working to transfer the mold to another supplier who can use it more effectively.

“We understand that it’s painful to transfer suppliers,” Lawson said. “That said, we’ve handled more than 150 mold transfers over the years, and we have the expertise a lot of people are missing.”

To learn more about how Performance Plastics can help transfer your mold, contact Rich Reed, our Vice President of Sales and Marketing, at (513) 321-8404 or RReed@performanceplastics.com.

Image you’ve just placed an order for two million injection molded parts to be manufactured over the course of a year and each part needs to be exactly the same. Or, that you have a part with a tolerance of under 0.001”. 

How confident are you that the manufacturer you’ve placed the order with can hit your specifications?  

At Performance Plastics, we couple our design expertise with automation and robotics to ensure tight tolerance part quality and consistency, as well as cost effectiveness. 

“Everything starts with the molding process and we’re among the best for getting that process tight,” says Jake Edwards, an automation engineer at Performance Plastics. “After molding, we’re constantly verifying that we’re within specifications. Automation allows us to efficiently inspect 100 percent of the products we make if needed.” 

Keeping It Tight 

For high-volume runs, we make sure every part that goes out the door is within the customer’s spec or our own – whichever is tighter. We measure dimensional tolerance, surface tolerance, even the way parts are positioned so they can go into the end product the same way every time.  

“We have parts that we make where we have to hold the tolerance to under 0.001 of an inch,” Edwards says. “And that can be over a run of 15 million parts throughout the year. We have to have a flat line of consistency.” 

But it’s not just high-volume orders that are checked via automation. Low volume runs with very tight tolerances for parts in critical applications are handled this way too. For example:  

• In the HVAC industry, we make parts that seal off chemicals in order to prevent dangerous leaks.  
• In the Industrial space, we make parts for plasma cutters that make sure two different types of gases are mixed correctly right at the nozzle. 
• In the Medical industry, we make parts that contain tissue samples. They need to be protected from contaminants to guard against false positives or negatives.  

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Robotics and Automation 

At Performance Plastics, we use a combination of automation and robotics across everything we do.  

“Robotics is automation,” says Edwards, “But automation is not necessarily robotics.” 

As previously described, automation is used to test tolerances. But we also have hard automation where cylinders, vacuums, and other actuators are moving product from place to place around the production facility – all with no robot in sight.  

However, robotics does make automation simpler. Take overmolding, for example. Many parts include battery contacts that run internally, a metal base, or features made from something other than plastics. A robot is can be fed these parts by an operator or other means. The robot will then place the parts in the mold to have the plastic part molded over top of the inserted non-plastic piece, pull the completed part out and re-insert new, quickly and reliably. 

Cost Savings 

Where automation and robotics comes together is at the bottom line – cost savings. For example, cycle times can be greatly improved because automation allows us to do multiple things at once, such as vision checks and leak checks at the same time.  

And this means one thing for our customers … cost savings.  

“Our reliability has gone up, which turns down the risk for our customers,” Edwards says. “With higher repeatability, the risk to the customer goes down. 

“If a customer finds 3 percent of a 1,000-piece order is out of spec, they’ll return the entire order. Sometimes the customer won’t allow one single piece to be out of spec – one bad part and the whole lot comes back. So, we need to be right the first time.” 

When it comes to robotics, not only can they be faster and more reliable, but they play a role in safety as well. The robotics keep operators out of hazardous environments on the manufacturing floor, which also impacts the bottom line.  

To learn more about Performance Plastics uses automation and robotics, contact Rich Reed, our Vice President of Sales and Marketing, at (513) 321-8404 or RReed@performanceplastics.com. 

Plastic is a fantastic material that is used in practically everything from playground equipment to lawn mowers to vehicles. But what about as a bearing or bushing?

Many engineers resist using plastic bearings, thinking they won’t stand up to harsh environments, extreme temps, heavy loads or high speeds. Some engineers believe in metallic bearings and are reluctant to change. However, high-performance plastic bearings from Performance Plastics are turning heads and changing minds.

Standard Metal Bearings

Polytetrafluoroethylene (PTFE)-lined metal bearings are made up of a thin, self-lubricating layer, embedded with PTFE, which is permanently bonded to an aluminum housing. However, the liner isn’t replaceable and can be scratched off by contaminates, which results in metal-to-metal contact between the bearing and shaft. This increases the coefficient of friction (COF), accelerates wear rates, and increases the risk of shaft damage.

How about injection molding the entire bearing or bushing from FEP, PVDF, or PFA?

High-Performance Plastic Bearings

With advancements in plastics, plastic bearings are gaining in popularity because they are more versatile, economical, and corrosion resistant. PEEK, Torlon® (PAI), PBI (polybenzimidazole), Ultem® (PEI), and PPSU (polyphenylsulfone) are all available as material options and suitable for use in plastic bearings. Plastic bearings are made of a thermoplastic alloy with a fiber matrix and solid lubricants, which account for their superior strength and consistently low COF.

High-performance plastic bearings offer a great many advantages:

• Cost savings, first and foremost. High-performance plastic bearings reduce overall cost because they resist wear, reduce maintenance costs, and can replace more costly alternatives.
• No need to lubricate. These bearings are self-lubricating, with lubricants embedded in the tiny chambers of the composite material. This eliminates the costs of both additional lubricants and continual maintenance.
• Plastic bearings can be reinforced with carbon fiber or fiberglass and can operate continuously at temperatures between -40°F and 500°+ F. But their thinner walls are better at dissipating heat. Plus, they’re less likely to deform under heavier weights.
• Corrosion Resistant. Plastic bearings are specifically designed to operate in harsh environments, surviving daily washdowns and caustic chemicals. Plus, their self-lubricating nature eliminates seal failure and contamination.
• Consistent COF. These bearings are designed to maintain a low COF over their lifetime, while their metal-backed counterparts can become scratched and increase the COF.
• Lighter weight. Plastics are significantly lighter than their metal alternatives, which can be up to five times heavier.
• Plastics can dampen vibrations with lubrication, becoming virtually silent.

To learn more about high-performance plastic bearings from Performance Plastics, contact Rich Reed, our Vice President of Sales and Marketing, at (513) 321-8404 or RReed@performanceplastics.com.

Performance Plastics specializes in precision injection molding of difficult parts, eliminating the need to machine. Our precise production process gives us the ability to injection mold difficult parts made from high performance plastic materials. If it can be molded, we can do it.
High performance plastic materials have ideal properties when it comes to durability. Plastics like polytetrafluoroethylene (PTFE/Telfon®) are known for their dielectric strength, low dissipation, chemical resistance, outstanding performance at elevated temperatures, and coefficient friction. However, their unique properties can make machining PFTE quite difficult. Dimensional changes, burrs, and consistency of machining can all be factors when you are creating a part out of these materials. Performance Plastics has found a way around the complications of machining PTFE by injection molding of other fluoropolymers.

At Performance Plastics, we are experts at precision injection molding. We have developed proprietary tool design software, processes and equipment enabling us to injection mold components having complex geometries made from challenging ultra- and high-performance thermoplastic materials and highly loaded compounds. We utilize a unique combination of extensive material knowledge, mold flow analysis, a design system and process expertise to eliminate or minimize the need for secondary operations.

The switch from a machined part to an injection molded part can be very beneficial to you. Not only does injection molding help lower costs, it also allows you to have highly efficient production, complexity in your part design, and enhances your strength. The ability to produce the parts at a very high level with a high output rate helps with cost efficiency and effectiveness. Injection molding can handle extremely complex parts, and uniformity, as well as the ability to make millions of virtually identical parts. Engineers can determine if the part needs to be flexible or rigid so that they can select the right material and adjust the integrating ribs or gussets. With the vast variety of materials and colors, making your color options almost endless.

Injection molding isn’t for every project, but it can be tremendously beneficial if you’re an engineer using more than 20,000 pieces of the same part year over year. At Performance Plastics, we serve a variety of industries, from Medical to Energy, Aerospace & Defense to Industrial, Electronics to Food & Beverage.

To learn about how precision injection molding can replace machined PTFE parts, contact Rich Reed, our Vice President of Sales and Marketing, at (513) 321-8404 or RReed@performanceplastics.com

As you’re designing and manufacturing your next application, wouldn’t it be ideal if you could analyze all the parts, compare them to the original drawings and get results quickly, without damage? At Performance Plastics, we have the ability to do this through industrial computed tomography (CT) scan. Giving us the ability to measure all aspects of your part, without having to damage it.

Industrial CT scanning gives you access to the inner workings of a part without having to destroy the original. The scanner rotates the part 360 degrees and uses X-rays to create a precise 3D model. This allows for a thorough analysis of object dimensions, porosity, wall thickness, assembly defects, comprehensive comparisons, and reverse engineering.

The CT scan can then be compared to the CAD model and to other parts. Plus, it can easily analyze surface variations and provide cross sections to reveal hidden features.

Performance Plastics now offer a variety of CT scan-related services:

• Part-to-CAD comparisons create a precise overlay of the scanned part to the original 3D part model database
• Part-to-part comparisons provide an overlay of two scanned parts to reveal dimensional deviation
• Void and inclusion analysis provides material and defect analysis showing void or inclusion size and locations
• Wall thickness analysis measures slight changes in the wall stock of complex parts without destructive testing
• Dimensional analysis provides full article inspections and reporting
• Reverse engineering capabilities that generate a 3D CAD file

Industrial CT scanning can be necessary during five different manufacturing stages. When you’re in pre-production, it can help with the project design and analysis. During production, you can use CT scanning to evaluate consistency. At the failure investigation stage, it will find defects. The CT scanner can run repeatability tests when you’re doing inspections. And if you need design adjustments or are doing further R&D, it can help with reverse engineering.

As for what Performance Plastics can handle when CT scanning:

• Maximum part size is 300mm diameter x 350 mm tall
• Scan time is typically less than one hour
• Accuracy (using Calypso) of 9+L/50 microns
• X-ray-based measurement system is non-contact
• Parts do not require potting

At Performance Plastics, we are problem solvers. We design and manufacture precision injection molded parts made with ultra-high-performance plastics such as Torlon®, PEEK, Ultem® and fluoropolymers. (FEP, PFA, PVDF). We specialize in molding parts with complex geometries and very tight tolerances for critical applications such as aerospace/defense, medical, and energy. We achieve this by combining a unique product design approach with proprietary process technology and state-of-the art quality control that provides our customers the “lowest cost solution.” Our engineers deliver results where others say, “it can’t be done.”

To learn more about if a CT scan can help your application, contact Rich Reed, our Vice President of Sales and Marketing, at (513) 321-8404 or RReed@performanceplastics.com