PEEK (polyether ether ketone) is a high-performance plastic. It handles heat, stress, and harsh chemicals better than most materials. That’s why it’s used in demanding fields like aerospace, medical, and electronics.
But when your design is complex—full of curves, cutouts, or thin walls—machining PEEK can become expensive and slow. Injection molding offers a smarter, more efficient way to make these parts.
The True Price of Intricacy: Hidden Costs in Machining Complex PEEK
Specialized Equipment & Expertise
Machining detailed PEEK parts usually needs 5-axis CNC machines. These machines can move and cut from many angles, but they’re costly to run. You also need skilled operators and programmers to get it right.
That adds labor time and raises project costs.
Tooling Challenges & Consumption
Complicated features often require custom tools. These tools can be fragile and may wear down quickly when cutting PEEK. That means more frequent replacements and higher tool costs over time.
Overview
The total cost of machining complex PEEK isn’t just about the raw material. You also pay for:
- Advanced machines
- Expert labor
- Custom tooling
- Higher tool wear
- Longer setup and run times
These add up fast, especially for parts with a lot of detail.
Unlocking Design Potential: The Freedom of PEEK Injection Molding
Injection molding allows molten PEEK to flow into a custom-made mold. This process fills even small or hidden spaces, forming the part in one shot.
That means you can design for function, not just for ease of manufacturing. You’re free to include:
- Undercuts
- Complex internal features
- Thin or varied wall sections
- Tight tolerance fits
- Smooth surface finishes
Instead of redesigning your part to suit a machine, the mold is built to match your original design.
Case Study Snapshot: From Multi-Part Machined Assembly to Single Molded PEEK Solution
Imagine a part made up of five separate machined PEEK pieces. Each piece must be cut, cleaned, and assembled. That takes time, adds cost, and creates more places where leaks or misalignment can happen.
By switching to injection molding, those five parts can often become one molded component. This saves:
- Part count
- Assembly steps
- Time and labor
- Material waste
- Risk of part failure
The new design may also offer better performance by removing seams and connections.
Conclusion
Complex PEEK designs don’t have to be limited by machining. Injection molding makes it easier to turn advanced ideas into precise, cost-effective parts.
If your current process is slowing you down or pushing up costs, it may be time to rethink how your parts are made. Injection molding can help you get both the performance and the design you need.
Let’s take a look at your design and see what’s possible.
