The Role of Fluoropolymers in Healthcare and Advanced Injection Molding
Fluoropolymers are a rapidly growing class of fluorocarbon-based polymers, valued for their exceptional biocompatibility, lubricity, sterilizability, chemical inertness, thermal stability, barrier properties, and high purity. These qualities make them indispensable in healthcare applications. However, compared to other resins, fluoropolymers are significantly more expensive and require specialized injection molding techniques due to their shear sensitivity, high melt temperatures, and fluorine outgassing when melted.
Among fluoropolymers, polytetrafluoroethylene (PTFE), widely recognized as Teflon®, has been in use since the 1940s. Over the years, newer resins have emerged to meet specific injection molding needs, including perfluoroalkoxy polymer (PFA) and fluorinated ethylene-propylene (FEP).
PFA: A True Melt-Processable Fluoropolymer
PFA was developed to provide a melt-processable alternative to PTFE while maintaining exceptional chemical resistance. It offers the smoothest and least wettable surface among fluoropolymers, making it ideal for laboratory equipment and precision applications. PFA’s optical transparency, flexibility, and superior electrical properties—boasting dielectric strength three to four times greater than PTFE—make it a preferred choice in various industries.
FEP: A Transparent, Weather-Resistant Fluoropolymer
Like PFA, FEP is also melt-processable and injection moldable. With a melting point of 260°C (500°F)—about 40 degrees lower than PFA—it provides excellent low-friction and chemical inertness comparable to PTFE. However, what sets FEP apart is its complete transparency and remarkable resistance to UV exposure, making it particularly well-suited for outdoor and weather-exposed applications.
Overcoming the Challenges of Fluoropolymer Injection Molding
Not all injection molders are equipped to handle the complexities of fluoropolymers like PFA and FEP. At Pexco LLC, we have developed innovative tools and processes to address these challenges. Our approach includes:
Advanced Hot Runner Systems & Tooling
Designed to minimize shear forces during the injection molding process.
Proprietary Corrosion-Resistant Metallurgy
Prevents damage from fluorine gas exposure, extending the lifespan of hot runner systems, tooling, and other critical components.
Direct-Gating, Multi-Runner Tool Design
Eliminates traditional sprues and runners, reducing material waste and improving cost efficiency.
By implementing these techniques, Performance Plastics has optimized the use of high-cost fluoropolymer resins, enabling material cost savings of 20% to 40%.
To discover how we can help you reduce resin costs while leveraging the unique advantages of PFA and FEP, visit www.pexco.com.