Case Study: Sinbo Precision's PEEK Material Parts Machining in Dongguan
In the realm of high-performance engineering materials, PEEK (Polyether Ether Ketone) stands out for its exceptional properties— 耐高温 (high-temperature resistance), 耐腐蚀 (corrosion resistance), and 高强度 (high strength)—making it a preferred choice for critical applications in industries like medical devices, aerospace, and industrial automation. Dongguan Sinbo Precision Mechanical Co., Ltd., a leading precision manufacturing provider since 2013, has mastered the art of machining PEEK materials to meet the most demanding specifications. With a 34,000㎡ facility, over 600 skilled employees, and nearly 500 advanced imported machines, Sinbo Precision continues to deliver innovative solutions for complex PEEK part requirements.
The Client Challenge: Medical-Grade PEEK Implant Components
Sinbo Precision partnered with a European medical device manufacturer developing a new generation of spinal fusion implants. The client required PEEK polymer parts with tight dimensional tolerances (±0.02mm), ultra-smooth surface finishes (Ra ≤ 0.4μm), and compliance with ISO 13485 medical standards. PEEK’s high melting point (343°C) and tendency to exhibit thermal expansion during machining posed significant challenges:
- Heat Management: Excessive friction during cutting could cause material degradation or warping.
- Surface Integrity: Achieving a bio-compatible surface finish without micro-scratches or burrs.
- Complex Geometry: The implant design included intricate internal channels and thin-walled structures (wall thickness ≤ 1mm).
Sinbo Precision’s Solution: Engineering Excellence for PEEK Machining
1. Material Handling & Pre-Processing
Sinbo’s team started by sourcing medical-grade PEEK rods (ISO 10993-compliant) with uniform molecular orientation. The material was annealed in a controlled oven to relieve internal stresses, minimizing the risk of post-machining deformation.
2. Precision Machining Process Development
- Tooling Strategy: Diamond-coated end mills and carbide drills were selected to reduce friction and wear. For rough machining, a 4-flute carbide end mill with a 3° helix angle was used at a cutting speed of 80m/min and feed rate of 0.05mm/tooth to balance material removal and heat generation.
- Cooling System: A combination of compressed air and minimal quantity lubrication (MQL) was applied to cool the cutting zone, keeping temperatures below PEEK’s glass transition temperature (143°C) to prevent thermal distortion.
- Finishing Operations: High-speed polishing with diamond abrasives achieved the required surface roughness. For the thin-walled sections, Sinbo used a custom-built fixture with vacuum clamping to ensure stability during machining, reducing vibration and improving dimensional accuracy.
3. Quality Control & Compliance
- Dimensional Inspection: Coordinate Measuring Machines (CMMs) with 0.001mm precision verified critical dimensions, including the internal channels and mating surfaces.
- Surface Analysis: Optical profilometers measured surface roughness, while dye-penetrant testing ensured no micro-cracks or defects.
- Material Traceability: Every batch of PEEK was tracked from procurement to delivery, with complete documentation for ISO 13485 compliance.
The Result: Medical-Grade Excellence and Operational Efficiency
Sinbo Precision delivered the PEEK implant components ahead of schedule, exceeding the client’s expectations:
- 100% Compliance: All parts met ISO 13485 standards and passed biocompatibility tests.
- Dimensional Accuracy: Tolerances were consistently within ±0.015mm, surpassing the required ±0.02mm.
- Surface Finish: Average Ra value of 0.35μm ensured smooth integration with human tissue, reducing the risk of inflammation.
The client praised Sinbo’s ability to balance technical precision with cost-effectiveness, noting a 20% reduction in machining time compared to previous suppliers. This partnership has since expanded to include PEEK components for orthopedic instruments and minimally invasive surgical tools.
Why Sinbo Precision Leads in PEEK Machining
- Material Expertise: Deep understanding of PEEK’s thermal and mechanical properties allows optimized process parameters.
- Advanced Equipment: Investment in DMG MORI 五轴 CNC machines (五轴联动加工中心) and automated inspection systems ensures repeatability for complex geometries.
- Cross-Industry Experience: Expertise in aerospace (PEEK for aircraft interior components) and industrial automation (wear-resistant PEEK gears) complements medical device solutions.
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