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About Pexco
Injection Molding
Fluoropolymer Molding
Where Ideas Take Shape
Pexco specializes in injection molding fluoropolymers including FEP, PFA, UHP PFA, PVDF, and ETFE for medical, pharmaceutical, semiconductor, and chemical processing applications requiring extreme chemical resistance, thermal stability, and material purity. Fluoropolymers present unique molding challenges due to their low melt viscosity, high processing temperatures, and corrosive byproducts that degrade conventional tooling. We have developed proprietary mold designs using specialized steels, advanced thermal control systems, and process refinements that enable successful molding of thin-walled, complex geometries in these demanding materials. Our biocompatible fluoropolymer capabilities serve medical device manufacturers requiring components that meet stringent regulatory standards for implantable devices and fluid contact applications.
Molding Process Challenges
Fluoropolymers are among the most difficult thermoplastics to injection mold successfully. Their low melt viscosity makes it challenging to mold thin-walled or intricate geometries without flash or short shots. High processing temperatures (600-750°F) require specialized thermal management to prevent material degradation while maintaining proper flow characteristics. During processing, some fluoropolymers generate hydrofluoric acid and other corrosive byproducts that rapidly degrade conventional mold steels, leading to dimensional instability and premature tool failure.
Pexco has developed comprehensive solutions to these challenges:
- Proprietary mold steels resistant to hydrofluoric acid corrosion and maintaining dimensional stability under high-pressure molding
- Advanced thermal control systems providing precise temperature management throughout the mold cavity
- Modified injection equipment optimized for low-viscosity materials with minimal shear degradation
- Process refinements including specialized resin additives and optimized cycle parameters
- Direct gating technology enabling multi-cavity tooling for economical production (see Direct Gating for details)
Biocompatible Fluoropolymer Molding
Medical device manufacturers increasingly specify fluoropolymers for components requiring biocompatibility, chemical resistance, and clarity. Pexco’s biocompatible fluoropolymer molding capabilities support:
Medical Device Components
- Catheters and fluid delivery systems
- Luer connectors and fittings
- Seals and gaskets for pharmaceutical equipment
- Implantable device components
- Surgical instrument components
- Diagnostic equipment housings
Regulatory Compliance: Our fluoropolymer molding processes support medical device manufacturing requirements including ISO 13485, USP Class VI biocompatibility testing, and FDA regulatory submissions. We maintain material traceability using 100% virgin-grade resins with full certification documentation.
Thin-Wall and Complex Geometries
One of fluoropolymer molding’s most significant challenges involves producing thin-walled components with complex internal features. The low melt viscosity that makes fluoropolymers difficult to mold also provides an advantage once proper tooling and processes are established. Pexco has developed techniques to successfully mold:
- Thin-walled tubing and cannulas with wall thicknesses below 0.015 inches
- Multi-lumen configurations for complex fluid routing
- Intricate internal geometries for connectors and fittings
- Over-molded assemblies integrating metal or ceramic components
Our capabilities include 8-cavity and higher multi-cavity molds with hot runner systems for high-volume production of complex fluoropolymer components, a capability few molders can achieve with these materials.
Fluoropolymer Extrusion
For fluoropolymer tubing, rods, and custom profile applications, Pexco offers comprehensive extrusion capabilities. See Custom Profile Extrusions for detailed information on fluoropolymer extrusion processes and stock products including PTFE, FEP, PFA, UHP PFA, and PVDF tubing, rods, and profiles available for same-day shipment.
Materials & Resins
Advanced Fluoropolymers for Injection Molding:
FEP (Fluorinated Ethylene Propylene)
Melt-processable with excellent chemical resistance, UV transparency, and gamma sterilizability. Continuous service to 400°F (204°C).
PFA (Perfluoroalkoxy)
Superior flow properties and temperature resistance to 500°F (260°C). Optimal for intricate geometries and high-purity applications.
HP PFA / UHP PFA (High Purity / Ultra-High Purity PFA)
Specifically engineered for semiconductor and pharmaceutical applications requiring extreme purity and contamination control.
PVDF (Polyvinylidene Fluoride)
Outstanding chemical resistance with enhanced mechanical strength. Excellent UV stability for outdoor applications.
ETFE (Ethylene Tetrafluoroethylene)
Superior mechanical properties with high light transmission. Used in architectural and chemical processing applications.
Why Choose Pexco?
Proprietary mold steels resistant to fluoropolymer corrosion
Advanced thermal management for high-temperature processing
Multi-cavity tooling (8+ cavities) with hot runner systems
Biocompatible fluoropolymer molding for medical devices
Thin-wall capabilities below 0.015 inches
100% virgin-grade resins with full material certification
ISO 9001:2015 certified, ITAR registered
Stock fluoropolymer products for same-day shipment
6 in-house tool and die centers for specialized mold design
Get Started
Contact Pexco’s engineering team to discuss custom tooling requirements for your application.