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PEEK Injection Molding Process Parameters
PEEK Injection Molding Process Parameters
PEEK injection molding involves five key parameters: temperature, pressure, speed, time, and mold/equipment setup. Exact settings vary by material grade (e.g., pure PEEK vs. glass or carbon fiber reinforced) and part design.
1. Temperature
- Drying: 150°C for 3 hours, or 160°C for 2 hours. Moisture must be below 0.02% to avoid bubbles or degradation.
- Barrel Temp: Unfilled PEEK: 360–380°C. Reinforced PEEK: 380–400°C. Do not exceed 420°C. Feed zone: 70–100°C for smooth feeding.
- Nozzle Temp: 385–395°C. Use a high-power heater to prevent cold slugs.
- Mold Temp: 175–205°C at surface. High mold temperature ensures proper crystallization, dimensional stability, and reduced internal stress.
2. Pressure
- Injection Pressure: 70–140 MPa (up to 200 MPa for thin/complex parts). Too high risks ejection damage; too low causes incomplete fill.
- Holding Pressure: 50%–80% of injection pressure (approx. 10 MPa). Hold for 10–30 seconds depending on wall thickness and gate freeze-off.
- Back Pressure: 0–1.0 MPa, just enough to compress melt and remove trapped air.
3. Speed
- Injection Speed: Medium to high. Use multi-stage injection based on part geometry to avoid shear overheating.
- Screw Speed: 50–100 rpm. Faster for unfilled PEEK; slower for reinforced grades to prevent fiber breakage.
4. Time
- Injection Time: A few seconds to 10–15 seconds, sufficient to fill the cavity completely.
- Holding Time: Set based on gate freeze-off to ensure proper packing.
- Cooling Time: 60–180 seconds, depending on wall thickness and mold temperature. Open mold only when cavity pressure nears atmospheric to avoid warping or scratches.
5. Mold & Equipment Setup
- Clamping Force: Unfilled PEEK: 50–80 MPa; fiber-reinforced: 65–140 MPa, based on projected area and cavity pressure.
- Screw L/D Ratio: 18:1 to 24:1 for uniform melting.
- Gate Design: Large gates (min 1mm, 2mm+ for reinforced), short and thick to reduce flow resistance and stress concentrations.
These are baseline values. In actual production, always adjust parameters based on specific machine, mold, and part requirements.
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