Although molding PEEK has historically been challenging, micromolding can, in fact, produce both simple and complex geometries using the material without extra cost, according to Scott Herbert, president of micromolding specialist Rapidwerks Inc. (Pleasanton, CA). In a presentation at the recent MD&M West conference sessions, Herbert spoke about "Precision Micromolding of PEEK Components" as well as associated benefits, obstacles, and considerations.

Characterizing a micromolded part as having a weight of 0.001 g or less and a maximum part size of 0.100 in diameter, Herbert noted that the micromolding process requires specialized machines, intricate tooling, specialize part handling and extraction, and inspection. The wrong way to mold a miniature part, he stresses, is by doing so on a conventional molding machine. Consequences of molding a micropart on a conventional machine may include minimal screw rotation, short or flashed shots, inconsistent process control, and other problems such as yield issues, material degradation, excessive material waste, and parting line flash.

Specialty molding equipment, in contrast, can produce high-quality micromolded PEEK parts. Key considerations when micromolding PEEK, however, include:

And while micromolding does have drawbacks in terms of upfront tooling costs, some design restrictions, and a dependence on tool completion for achieving part to market, it offers less material scrap and shorter cycle times than micromachining a PEEK part, according to Herbert.

Learn more about micromolding in "Incredible Shrinking Parts Cut Molding Applications Down to Size," "It's a Small World After All," and "10 Tips for Medical Micromolding" from MPMN's archives. --Shana Leonard