PEEK (polyether ether ketone) is known for its strength, heat resistance, and chemical durability. It’s a favorite among engineers who need high-performance parts.
But it comes at a steep price. A single 3-inch round, 8-foot stick of PEEK can cost around $3,000 (source: Victrex). And when you machine parts from that stick, a lot of material can end up as waste.
This article looks at how injection molding helps you get more value from every gram of PEEK by using material more efficiently.
Why Every Gram of PEEK Matters: Understanding the Cost of Machining Waste
PEEK is expensive—every gram counts.
When you machine a part, you remove large sections of material. The cuttings and shavings, also called swarf, are wasted. For a material like PEEK, that’s not just scrap. It’s lost money.
If you’re in engineering or procurement, you know how quickly these material losses can impact your budget—especially when working with high-cost plastics like PEEK.
The Mechanics of Savings: How Injection Molding Preserves Your PEEK Investment
Precision Material Delivery
Injection molding melts PEEK pellets and injects them directly into a mold. The machine delivers just the amount needed for each part.
There’s no need to cut away extra material. That means less waste and better use of your raw stock.
Runner Systems vs. Bulk Removal
In injection molding, the runner system channels the molten PEEK into the mold. This system does produce some waste (runners and sprues), but it’s usually small.
In some cases, this waste can even be reused, depending on the part and PEEK grade.
By comparison, machining a PEEK rod creates a large amount of non-reusable chips. That waste can be 30–60% of the original rod, depending on the design.
Is PEEK Injection Molding Right for Your Application? A Cost-Benefit Perspective
Volume Break-Even Points
Injection molding requires a tool, which can be expensive to make. But if you’re producing medium to high volumes, the savings add up.
Once the mold is made, each part is cheaper to produce—especially when you factor in the reduced material waste.
Complexity Without Penalty
Complex parts often require more cutting when machined, which leads to more waste. But with injection molding, complex shapes don’t mean more material loss.
That makes molding a better fit for parts with fine details or intricate geometries.
Beyond Material: Secondary Cost Reductions with PEEK Injection Molding
Injection molding creates near-net-shape parts. This means they come out of the mold already close to their final size and shape.
As a result, you may need fewer finishing steps—less trimming, sanding, or drilling. This saves time, reduces labor costs, and helps move parts through production faster.
Conclusion
PEEK is a valuable material, but machining it from solid stock can lead to major waste and rising costs.
Injection molding gives you a smarter way to make parts. It improves how you use material and reduces the steps needed after molding. If you’re still cutting parts from expensive PEEK rods, it may be time to rethink your approach.
Let’s look at your PEEK project and see how much you could save.
