You’ve built a working PEEK prototype. That’s a big step. Chances are, you used machining to shape that first part. Machining is fast and flexible, so it’s great for testing designs.
But if demand is growing, machining quickly runs into limits. It gets slower, more expensive, and harder to scale. Making hundreds—or thousands—of the same PEEK part this way can cause delays and push costs too high.
Injection molding is a better fit when you’re ready to move from prototype to production.
The Prototype-to-Production Gap: Why Machining PEEK Doesn’t Scale Cost-Effectively
Machining works well in small numbers. But at larger volumes, it runs into problems.
Each part takes time to set up, program, and cut. Even with skilled workers and good equipment, those steps add up.
You also lose material with each part. PEEK stock is expensive—some 3-inch rods can cost around $3,000 for 8 feet. If you only get a few parts from that, waste becomes a major issue.
These factors make machining too slow and costly for full-scale production.
PEEK Injection Molding: Engineered for Mass Production Efficiency
Rapid Cycle Times, Exponential Output
Injection molding can produce a PEEK part in just minutes. Once the mold is set up, each cycle creates a new part—no extra cutting or finishing steps needed.
You can make hundreds or thousands of parts per day, not per month.
Automation and Reduced Labor Per Part
Injection molding systems are highly automated. That means:
- Less hands-on time
- Fewer setup steps
- Lower labor costs per part
Compared to machining, where each part may need individual attention, molding is much more efficient.
Overview
Injection molding is built for high-volume production. It’s faster and requires less manual work, making it ideal for scaling up.
The Economics of Scale: How PEEK Injection Molding Drives Down Unit Costs
The mold tool for injection molding is an investment up front. But after that, each part costs less and less to make.
Why? Because:
- Material is used more efficiently
- Labor is lower
- Parts are made faster
At higher volumes, the price per part drops sharply. A simple graph would show a steep decline in cost per unit as volume rises.
If you’re interested, we can help calculate the return on investment (ROI) for your specific part.
Ensuring Consistent Quality Across High PEEK Volumes
When machining many PEEK parts, it’s easy for slight differences to creep in. Tool wear, small changes in setup, or programming errors can affect consistency.
Injection molding offers much tighter control. Once your mold is tuned, every part is nearly identical in:
- Dimensions
- Surface finish
- Material strength
This makes it easier to meet quality standards and avoid rework or scrap.
Conclusion
Moving from prototype to production takes more than just repeating the same steps—it takes the right method.
Injection molding helps you make high-quality PEEK parts at scale. It cuts down cost, speeds up production, and keeps quality high.
If you’re ready to scale your PEEK design, let’s talk about how injection molding can support your next step.
