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PEEK Injection Molding

As an ultra-high-performance specialty engineering plastic, PEEK plastic has perfect physical and chemical properties. PEEK has become a core material in fields such as aviation and semiconductor industries. Through precision injection molding technology, PEEK can meet stringent demands ranging from minimally invasive surgical instruments (<0.1mm wall thickness) to deep-well exploration seals (150MPa pressure).

An NDA can be signed if needed before the quotation.

Why Choose PEEK Injection Molding

PEEK injection-molded parts demonstrate remarkable performance in extreme environments compared to common plastics like PP, ABS, and nylon. While ordinary plastics cannot withstand high temperatures and are prone to deformation and corrosion, PEEK maintains stable operation at 260°C. Additionally, PEEK injection-molded products feature high strength and resistance to strong acids. This is why PEEK plastic is ideal for manufacturing precision wear-resistant components such as aerospace engine parts and medical implants.

High-Temperature Resistance: Continuous service at 260°C, short-term tolerance up to 300°C.
Mechanical Strength: Tensile strength 90-100 MPa, 4 times the wear resistance of PTFE
Chemical Stability: Resistant to strong acids (except concentrated sulfuric acid) and organic solvents
Dimensional Stability: Shrinkage rate 0.1-0.5%, thermal expansion coefficient similar to aluminum metal
Flame Retardancy: UL94 V-0 rating, halogen-free flame retardant

What Products Can Be Made with PEEK Injection Molding?

Although PEEK injection-molded parts are costly, they are irreplaceable in these high-performance applications:

Medical Field

Application

Why?

Aerospace

Application

Why?

Industrial Equipment

Application

PEEK injection molding can also produce precision valve cores for coffee machines, foldable smartphone hinges capable of over 100,000 open/close cycles, and deep-sea drone housings that withstand high-pressure underwater environments. With the continuous development of products in AI and robotics, the role of PEEK injection molding will become even more prominent.

PVC

ABS

POM

PBT

PMMA

PEEK

We can mold materials far beyond this

When Can You Avoid Using PEEK Material?

If your product design faces limited budget, material shortages, or performance overkill, these alternatives might be more cost-effective.

Scenario 1: Limited Budget – Can a Cheaper Material Be Used?

Criteria: When your part operates below 150°C and does not contact strong acids / alkalis.

Recommended Solution:

Alternative: PEI (cost reduced by 30%-40%)

Real-World Case: After switching to PEI for an industrial gearbox:

Scenario 2: PEEK Material Shortages – What to Do?

Emergency Solutions (priority order):

Comparing PEEK injection molding and PEI injection molding

The core of comparing PEEK and PEI in the field of injection molding lies in their performance and cost. Both plastics exhibit high temperature resistance, corrosion resistance, and similar properties. While their performance is comparable, there is a significant cost difference (typically, PEEK is 2-3 times more expensive than PEI). Although other plastics (e.g., PPS, LCP) may partially match their performance, they cannot replace PEEK and PEI in critical metrics (e.g., biocompatibility, long-term fatigue resistance). Therefore, engineers must balance performance and cost to select the optimal material.

Dimension	PEEK	PEI	Design Decision Points
Thermal Performance	Continuous use temp: 250°C	Continuous use temp: 170°C	PEEK is mandatory for high-temperature environments (>200°C).
Thermal Performance	Melting point: 343°C	Tg: 217°C
Mechanical Performance	Tensile strength: 100 MPa	Tensile strength: 85 MPa	Choose PEEK for high-load applications; PEI for impact resistance.
Mechanical Performance	Flexural modulus: 3.6 GPa	Flexural modulus: 3.0 GPa
Processing Parameters	Barrel temp: 360-400°C	Barrel temp: 340-370°C	PEI has shorter cycle time and suits thin-walled complex parts.
Processing Parameters	Mold temp: 160-180°C	Mold temp: 140-160°C
Chemical Compatibility	Resistant to strong acids (except concentrated H₂SO₄) and organic solvents	Resistant to fuels and weak acids; poor alkali resistance	Use PEI for fuel exposure; PEEK for harsh chemical environments.
Cost & Process Challenges	Material cost: High	Material cost: Medium	Prioritize PEI under budget constraints but avoid prolonged heat exposure.
Cost & Process Challenges	Requires high-temp molds to prevent cold slugs	Prone to flash; requires precise pressure control
Key Applications	Oil seals, surgical tools, satellite components	Automotive sensor housings, PCB insulators, steam-sterilized equipment	Use PEEK for medical implants; PEI for electronics encapsulation.

How to Choose a Reliable PEEK Injection Molding Service Provider?

It involves many challenges for startups or design companies to find a PEEK injection molding supplier:

It can lead to severe consequences when choosing an unqualified PEEK processor. For example, a rumored medical company once partnered with a molding factory that deviated by just 2℃ in temperature control, causing $1.2 million worth of implant components to crystallize and embrittle in bulk, delaying the project by over six months.

1. High-Temperature Precision Molding Expertise

PEEK molding requires maintaining a melt temperature of 380-400℃ consistently. Retrofit equipment in generic factories often suffers temperature fluctuations exceeding ±5℃. First Mold employs all-electric injection machines with closed-loop temperature control and achieves stability within ±1.5℃. In 2024, 13 out of 17 PEEK projects involved ultra-thin walls, achieving a first-shot success rate of 92%+ thanks to this precision.

2. Uncompromising Material Traceability

Approximately 35% of so-called “PEEK” parts on the market are adulterated with cheaper PEI or PPSU. Reputable suppliers provide UL certification for every material batch. FirstMold not only discloses raw material test reports but also allows clients to participate in third-party FTIR spectroscopy verification, eliminating counterfeit risks at the source.

3. Risk-Controlled Agile Response

When a robotics company urgently needed to redesign PEEK joint molds within 48 hours due to design changes, First Mold leveraged pre-engineered modular hot runner systems to slash mold modification time from the industry average of 72 hours to just 19 hours. This agility is powered by a standardized database of 50+ PEEK-dedicated mold designs.