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  • PEEK® Use in Medical Applications

    Thermoplastic medical spinal implant component, precision thermoplastic medical check valve, non-contaminating Thermoplastic medical valve component, precision thermoplasticmedical spinal implant component, non-contaminating medical spinal implant component
    High Precision, PEEK, Thermoplastic Medical Spinal Implant Component

    PEEK® is an organic thermoplastic polymer that offers excellent mechanical and chemical resistance properties because of its chemical make-up.  PEEK® is short for polyether ether ketone, which means it’s a member of the polyaryletherketone family. These polymers are notable for their phenylene rings and oxygen bridges, which result in resilience, durability and strength.

    PEEK® is great for medical applications because it is one of the few high-performance polymers that is a bio-material – it is highly resistant to radiation which allows for easy sterilization.

    • Biocompatibility – PEEK® is a proven biomaterial, which means it is considered safe for use with in vivo applications. PEEK® shows no signs of cytotoxicity, genotoxicity, or immunogenetics.  The material has been successfully in use for over 20 years.
    • A favorable flexural modulus – Compared to metals such as titanium, stainless steel and other metal biomaterials, PEEK® is much more flexible. It behaves much more like bone in how it flexes and bears weight.  It does not cause stress shielding in nearby bone.
    • Pure radiolucency – PEEK® renders transparent on X-rays, CT and MRI scans – which makes it easy for surgical teams to track the positioning of implants and detect complications.

    Many medical device manufacturers now use PEEK® as a way to improve the biocompatibility of load bearing implants.  PEEK® is increasingly becoming the new standard biomaterial across a range of medical, orthopedic, and dental applications.

    Performance Plastics’ team of experienced engineers possess the expertise to design and manufacture technically challenging projects and offer complex solutions within the medical industry.

    For more information on how Performance Plastics can assist in your material selection challenges, please contact Rich Reed, VP Sales & Marketing at 513.321.8404 or rreed@performanceplastics.com.

  • The real cost of making an injection mold

    When starting to produce a new product, it’s important to decide on the type of process you will use for the manufacturing process.  While injection molding is a very cost-effective process, the initial startup cost of the mold is often a barrier of entry.

    Injection molding is a manufacturing process that is very efficient for producing parts in large volume.  It is typically used in the mass production process where the same part is being created in the thousands or even millions.

    Upfront costs tend to be very high due to the design, testing, and tooling requirements.  If you are going to produce parts in high volumes, you want to make sure you get the design correct the first time. So, what are the costs associated with producing an injection mold?

    • Choice of Resin

    One of the biggest factors that effect the price of the plastic injection molding process is the type of plastic resin used in manufacturing.  The choice of material will change the price based on color, compounding, and additives.  The most abrasive or corrosive the material, the most expensive the mold.

    • Complexity

    The more intricate the component, the more difficult it is to design the manufacturing process.  Part complexity, tolerances, number of undercuts as well as surface finish all effect the cost.

    • Size

    The size of the component also drives the price.  Larger parts require larger, more expensive molds, as well as more material to manufacture.  Larger molds also take longer to make, which increases the costs.

    • Mold Material

    The material the mold is made from significantly impacts the price.  Short production molds are usually made from less expensive materials such as aluminum.  Long production molds require molds made from more durable and expensive materials like steel that will retain their features across several years.

    • Cavities

    The higher the number of cavities – the higher the production costs.  Experienced mold designers can maximize cavitations to enhance productivity and lower costs even for the most intricate parts and components.

    • Mold Base

    The base of the mold is the case used for holding all the components, inserts and cavities of the mold.  The price of the mold base depends on the type of steel and the size of the mold.

    At Performance Plastics, we know how important it is to make the correct decisions when designing a mold.  We have a team of process experts who work with our clients to design and assist in the mold process. We focus on the total cost of ownership of a mold, production capacity, longevity, functionality, as well as initial capital expense.

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

  • Meet our new Team Member – Lori Bragg – Senior Customer Service Coordinator

    Performance Plastics is pleased to announce the addition of our new Senior Customer Service Coordinator – Lori Bragg. Lori joins Performance Plastics with over 30 years’ experience, B.A. in Communications, and working with industry leading companies in Cincinnati, Ohio.

    “Lori brings a wealth of experience in B2B manufacturing, inside sales, ERP processes, and customer service to our company” said Rich Reed, Vice President of Sales and Marketing, “The addition of Lori as a Senior Customer Service Coordinator is a representative of our continued commitment to provide our customers with the excellent customer service they have come to expect from PPL.  We are excited to have Lori join us and look forward to continued growth.”

    Lori stated, “I look forward to helping Performance Plastics continue to meet our customers’ expectations by providing the highest level of service.”

    Performance Plastics Ltd is a custom injection-molder of high-performance polymers for mission critical markets including Aerospace/Defense, Medical, and Precision Industrial.

     

  • Injection Molded PFA for Semicon Meets F-57 Requirements

    At Performance Plastics, we hold the quality of our products to the highest standards. We know that quality is critical for our customers, so we go above and beyond to make sure our customers products are no less than ideal.

    Manufacturing quality products is key to maintaining long term relationships with our customers. We take the time after injection molding a product to test the quality and to quantify compliance standards. This extra time assures that we are meeting all the specifications of our customers’ products.  To this end, we maintain SEMI F57 compliance for our customers PFA (Perfluoroalkoxy) and PTFE (polytetrafluoroethylene) injection molded products.

    SEMI F57 compliance is a specification for polymer materials and components used in ultrapure water and liquid chemical distribution systems. The SEMI F57 standard requires fluid-component manufacturers to follow best practices in material science and not contaminate UHP processes with extractable ions, metallics or total organic carbon (TOC). The standard also covers surface roughness, particle contribution, metallic contamination, and reliability testing.

    SEMI F57 Standards ensure compliance as they identify permissible limits for seven different aqueous leachable anions: bromide, chloride, fluoride, nitrate, nitrite, phosphate and sulfate.  Additionally, the standards measure for elevated levels of total organic carbon (TOC) which can have negative effect on silicon oxidation.

    In order to ensure that we maintain SEMI F57 compliance, we have added new, additional quality testing steps. The steps occur during the molding, cleaning, drying and packaging processes. These quality tests are crucial – they certify that each product injection molded by Performance Plastics follows the SEMI F57 standards and will not contaminate ultrapure water and liquid chemical distribution systems.

    For more information on how Performance Plastics can help your injection molded PFA or PTFE product achieve SEMI F57 compliance, contact Rich Reed our Vice President of Sales and Marketing, at (513) 321-8404 or RReed@performanceplastics.com.

  • EnduroSharp® Torlon® Aircraft Maintenance Tools – Why Use a Pneumatic Tool

    EnduroSharp® has improved the way aerospace maintenance professionals remove sealants and adhesives from substrates and fasteners.  EnduroSharp® resharpenable, non-marring tools are made from Torlon®, a high strength polymer, creating a non-metallic blade tool that will not damage composite structures during use.

    Many of our EnduroSharp® tools can be used in conjunction with a pneumatic tool.  A pneumatic tool is one that’s driven with the assistance of compressed air rather than electricity.  Pneumatic tools rely on air compressors to provide a burst of air to perform its operation. A pneumatic tool can operate indefinitely as long as the attached air compressor can deliver the required volume and pressure without interruption.

    Pneumatic Tools are very strong air powered tools and provide the user with a tremendous amount of labor and time saving torque.

    Pneumatic tools provide many advantages:

    • Main advantage is they are far less expensive than their electric alternatives.
    • Provide a degree of safety in wet areas where electric motors can be dangerous.
    • Lighter in weight than their electric counterparts.
    • Pneumatic tools can deliver large amounts of torque or operate for long durations of time.
    • More flexible than electric – nearly all air-driven tools use the same ¼” quick connect fittings.

    Generally, pneumatic tools are smaller, more versatile, easy-to-use and safer than traditional electric tools.  Since pneumatic tools are usually lighter, the user is able to have better control and experience less fatigue and strain.  They are also able to withstand various elements such as dust, heat and water better than electric tools.

    The EnduroSharp® Pneumatic Tool for Scraper Blades is just one of the many products offered in the EnduroSharp® Product line. Contact Rich Reed,  Vice President of Sales and Marketing, at (513) 321-8404 or RReed@performanceplastics.com, for more information.

     

  • PEEK, PAEK and PEI are Great Alternatives During Material Shortages

    Navigating supply chain issues in this economic environment where there are rampant material shortages is an ongoing challenge. But many commonly used engineered resins may serve well as replacements for your application. Performance Plastics are experts in material selection and can assist your organization in choosing the best material based on the functionality of your part.

    PEEK (Polyether Ether Ketone), PAEK (Polyaryletherketongs) and PEI (Polyetherimide) are high performing engineering thermoplastics that offer a unique combination of thermal stability, chemical resistance, and excellent mechanical properties.

    PEEK is extremely tough and has very high impact strength.  Due to the crystalline nature of the material, a high degree of mechanical properties is retained close to their melting temperature.  The also have a low creep and good wear properties.  It is also known for excellent chemical resistant during hydrolysis. PEEK is actively used in metal to plastic replacement applications.

    PAEK is a high thermal stability material that offers high strength and high resistance to oxidation. It offers better solvent resistance and is more amorphous based on its semi-crystalline structure.  This makes it an excellent choice for medical components, sea equipment and valve components.

    PEI is a high-performance engineering plastic that offers outstanding thermal, mechanical and chemical properties.  It is often the best choice where high mechanical strength is needed in conjunction with high temperature, corrosion and wear resistance. This makes PEI an excellent alternative for applications requiring tight tolerances and low warp such as medical devices, scientific equipment parts and semiconductor equipment components.

    Performance Plastics are specialists in high performance plastics engineering for many industries including medical, defense and industrial applications. We partner with our customers to offer solutions to some of the most challenging applications.  For more information, please contact Rich Reed, Vice President of Sales & Marketing at 513.321.8404 or email rreed@performanceplastics.com.

  • All You Need to Know About EnduroSharp Torlon Gap Filler Removal Discs

    EnduroSharp® has changed the way aerospace maintenance professionals remove sealants and adhesives from substrates and fasteners. EnduroSharp® tools are made from Torlon®, a high strength polymer, creating a non-metallic tool that will not damage composite structures during use. The EnduroSharp® lineup consists of a variety of scraper blades, gap blades, reamers, cutters, bits, and discs for removal of adhesives on aircrafts. The product line also includes a variety of kits containing a selection of parts and sizes.

    Traditionally, aerospace maintenance professionals removed sealants and adhesives from  gaps utilizing solvents and/or abrasive scraper tools.  Solvents are very dangerous in that they may dissolve unintended materials, and produce hazardous fumes.  Abrasive scraper tools are often hard to control and may cause unintended substrate damage.

    EnduroSharp® Torlon® Gap Filler Removal (GFRD) Discs are designed for use with a pneumatic tool. The tools provide aerospace maintenance professionals with an effective method of safely removing flexibilized epoxy gap materials as well as cutting or scoring thick elastomeric coatings without damaging composite substructures.

    EnduroSharp® Torlon® Gap Filler Removal (GFRD) Discs are shipped 4 parts per box.

    The EnduroSharp® Torlon® Gap Filler Removal Discs are just one of the many different items offered in the EnduroSharp® product line. Contact Rich Reed our Vice President of Sales and Marketing, at (513) 321-8404 or RReed@performanceplastics.com,  for more information on our EnduroSharp® kits and products.

  • It’s Not Tight Tolerance Unless You Can Measure It – Industrial CT Scanning

    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 experts in injection molding, specializing in high performance plastics for medical device components. Our proprietary tool design software, processes and equipment enable us to injection mold components having complex geometries made from challenging ultra, high-performance thermoplastic materials, and reinforced compounds.

    For more information on Performance Plastic’s capabilities, please contact Rich Reed, Vice President of Sales, and Marketing at 513.321.8404 or email at rreed@performanceplastics.com  

     

  • EnduroSharp®Nonmetallic (Torlon®) Aircraft Maintenance Tools

    EnduroSharp® has changed the way aerospace maintenance professionals remove sealants and adhesives from substrates and fasteners. EnduroSharp® resharpenable tools are made from Torlon®, a high strength polymer, creating a non-metallic blade tool that will not damage composite structures during use.

    The lack of reliable and effective nonmetallic material removal tools available to maintainers drove the continued use of unapproved tools and/or methods for removing materials from aerospace vehicles. The use of metallic tools has resulted in damage to vehicles, both short term and long term, causing the need for expensive repairs and reduction in vehicle availability.

    Because of this need, The University of Dayton Research Institute under contract to the Air Force Research Laboratory developed a series of nonmetallic material removal tools under the “EnduroSharp” trademark manufactured from Torlon thermoplastic manufactured by Solvay Engineered Plastics and produced by Performance Plastics of Cincinnati OH.

    Attached is the published white paper outlining the development of the “EnduroSharp®” line of Torlon® non-metallic aircraft maintenance tools.  In this paper you will find:

    • Abstract
    • Background
    • Prototype Development Path
      • Gap Filler Removal Bits
      • Torlon Scraper Blades
      • Torlon Gap Blades
    • Results
    • Conclusions

    To review the white paper in full, please click here.

    EnduroSharp® Products are currently approved for use by numerous governmental and corporate defense organizations including the USAF, USMC, USN, USCG, Lockheed Martin, Boeing, and Dassault.

    EnduroSharp® Products are now available as individual components, tools and consumables or as Aviation Kits.

    For more information on the EnduroSharp® line or Torlon® Aircraft Maintenance Tools, please contact our Vice President of Sales and Marketing, at (513) 321-8404 or visit our website at www.stg-performanceplastics-stage.kinsta.cloud/endurosharp.

     

  • Benefits of Reshoring for Medical Device Manufacturers

    Medical devices must be dependable and safe, and moving operations back to the United States allow companies to have better control over the entire operation – procurement, engineering, production, and distribution.  The result is a higher standard of quality in products.  Medical device companies and other advanced industries need to have extensive and precise control over the entire supply chain of their products.

    As an American small business, Performance Plastics is pleased to see the trend of manufacturing operations moving back to the United States.  A range of economic and strategic factors due to the recent epidemic have tipped the scales exponentially since 2020.

    While there are many benefits of reshoring, some of the most important reasons include:

    • Greater Control of Supply Chain

    Getting all your moving pieces to work seamlessly can be a near impossible task, especially across language and time zone barriers.  One of the primary advantages of reshoring is that it allows you to tighten your supply chain.

    • Reduced Lead Times

    The greater the distance between where your device is manufactured and where you are located, the longer you can expect your lead time to be.  However, distance is not the only factor.  When moving from one country to another, inspection and transportation times between countries can add up to 50% to your lead time.

    • Fewer Import Tariffs

    Import tariffs vary from administration to administration, but they will always be in place.  The recent increase in tariffs have caused the cost advantages of manufacturing offshore to shrink.

    • Reduced Energy Costs

    Recent changes to international gas and power prices have drastically increased the prices of manufacturing and transportation from other countries.  Impact on the environment and achieving higher sustainability are very important to consumers.

    • Potential to Improve Brand Perception

    Although we live in an international community, the origin of a product still has an impact on the perception of quality.  Some lower cost manufacturing countries even have a perception of being “dangerous”.

    Medical devices necessitate the highest quality standards possible, which can’t always be regulated in an offshore manufacturing environment.  The vast global, economic, legal and social changes are all very dynamic and unpredictable in nature – making relocating operations a more sustainable, stable and efficient choice.

    At Performance Plastics, we are experts in injection molding, specializing in high performance plastics for medical device components. Our proprietary tool design software, processes and equipment enable us to injection mold components having complex geometries made from challenging ultra, high-performance thermoplastic materials, and reinforced compounds.

    For more information on Performance Plastic’s capabilities, please contact Rich Reed, Vice President of Sales, and Marketing at 513.321.8404 or email at rreed@performanceplastics.com