Processing Technology and Application of PEEK Materials

Processing Technology and Application of PEEK Materials

In multiple engineering fields, PEEK is often used to achieve performance and demanding applications similar to those provided by metals. For example, in various applications that require long-term compression resistance, wear resistance, tensile strength, and high performance, the potential advantages of PEEK materials can be utilized in the oil and gas industry. Continue reading to learn about the processing techniques and applications suitable for peek materials.

Three Common Process Types for PEEK Material Processing

One of the reasons why PEEK is widely used in engineering applications is the availability of multiple options and processing conditions, namely processing, fuse manufacturing, 3D Printing, and injection molding, to manufacture the required geometric shapes in organic and water environments

1. PEEK CNC Machining

CNC (Computer Numerical Control) machining consists of different variants of multi axis milling, turning, and electrical discharge machining (EDM) to obtain the desired geometric profile. The main advantage of these machines is that they can be controlled through advanced controllers and computer-generated code.

CNC machining provides the opportunity to create complex geometric shapes of different materials, from plastic to metal, while meeting the required geometric tolerance limitations. Mold PEEK materials can be processed to obtain complex geometric contours, as well as medical and industrial grade PEEK. CNC machining provides high precision and repeatability for PEEK parts.

PEEK is stronger and harder than most polymers, but softer than most metals. This requires the use of fixtures during the machining process to ensure precise machining. PEEK is a high heat engineering plastic, and the heat generated during the processing cannot be fully dissipated. This requires the use of technology to avoid problems caused by inefficient heat dissipation of materials.

These preventive measures include deep hole drilling and the use of sufficient coolant in all machining processes. Petroleum based and water-based coolants can be used.

Another important factor to consider is tool wear during processing PEEK, compared to processing a few other compatible plastics. The use of carbon fiber reinforced PEEK grade has a greater adverse effect on the tool. This situation requires the use of hard alloy tools to process ordinary grade PEEK, while diamond tools are used to process carbon fiber reinforced PEEK grades. The use of coolant can also improve tool life.

2. PEEK 3D printing

3D printing, also known as additive manufacturing, typically refers to the use of adding materials in layers to create 3D geometric shapes from computer-aided design models.

PEEK material is suitable for 3D printing. Melt deposition modeling (FDM) is the most widely used 3D printing method for PEEK materials. Some progress has also been made in printing PEEK in powder form through selective laser sintering (SLS).

3D printed PEEK products have good wear resistance. Fibers produced by different manufacturers can provide different properties. 3D printing components provide a unique opportunity for healthcare professionals to produce customized implants to meet the needs of individual patients. 3D printed PEEK material components are used in different spatial systems. It also demonstrates the capabilities that 3D printed PEEK materials can provide.

However, to print PEEK materials, a high-temperature nozzle with a temperature exceeding 300 ℃ is required. In addition to the high-temperature nozzle, a heating bed is also needed to continuously maintain the heating state of the material. Some printers also use a heating chamber to achieve this goal. The heating chamber can better control the room temperature and continuously provide heat.

3. PEEK injection molding

Injection molding refers to the manufacturing of thermoplastic parts by injecting molten material into pre-existing molds. It is used for mass production of parts. The material is melted in the heating chamber, mixed with a spiral screw, and then injected into the mold cavity, where the material cools to form a solid shape.

Granular PEEK materials are used for injection molding and compression molding. The drying procedures required for granular PEEK produced by different manufacturers may vary slightly, but typically drying at 150 ° C to 160 ° C for 3 to 4 hours is sufficient.

Standard injection molding machines can be used for injection molding of PEEK materials or mold peeks, as these machines can achieve heating temperatures ranging from 350 ° C to 400 ° C, which is sufficient to meet almost all PEEK grades.

Special attention should be paid to the cooling of the mold, as any inconsistency can cause changes in the structure of PEEK material. Any deviation from the semi crystalline structure can lead to suboptimal changes in the characteristic characteristics of PEEK.

For example, using cold molds can lead to the formation of amorphous structures in PEEK. The optimal mold operating temperature for most grades of PEEK is considered to be between 170 ° C and 200 ° C to obtain a semi crystalline structure.

Application scenarios of Peek products

1. Medical field

Due to the biocompatibility of PEEK materials, they are widely used in medical applications, including implanting components into the human body at different times. Components made of PEEK material are also used in different drug delivery systems.

Other medical applications include dental healing caps, pointed washers, trauma fixation devices, and spinal fusion devices.

2. Aerospace field

Due to the compatibility, thermal conductivity, radiation resistance, and chemical resistance of PEEK with ultra-high vacuum applications, parts made of PEEK plastic are widely used in aerospace applications due to their high-performance tensile strength.

3. The automotive industry

Bearings and different types of rings are also made of PEEK. Due to its excellent weight to strength ratio, PEEK is used to manufacture parts for racing engine sets

4. Insulation of wires and cables/electronic applications

The cable insulation layer is made of PEEK and can be used for applications such as aircraft electrical systems in manufacturing projects.

conclusion

As a semi crystalline organic polymer belonging to the PAEK family, PEEK has mechanical, thermal, chemical, and electrical properties, making it the preferred material for multiple engineering applications. PEEK comes in various forms (rod shaped, filamentous, granular) and can be processed through CNC machining, 3D printing, and injection molding. WayKen has extensive experience in PEEK processing and is always ready to provide support in your PEEK project. Contact us today to obtain a quote.