What is ULTEM cutting process? Explaining the advantages, cautions, and how to choose a contractor.

ULTEM is one of the super engineering plastics with well-balanced properties.

You may be considering using ULTEM to manufacture products but want to know "the characteristics of ULTEM and what kind of products it is suited for," or "the advantages and cautions of ULTEM cutting.

This article will provide an overview of ULTEM as a material, its merits and demerits, as well as the advantages and cautions of cutting ULTEM.

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ULTEM is a type of PEI (polyetherimide)

ULTEM is a type of PEI (polyetherimide), an amorphous super engineering plastic.

It has a good balance of many properties, including light weight (less than half that of aluminum), high strength and weight ratio.

ULTEM is a material developed by General Electric (GE) of the United States and currently produced by the Saudi Basic Industries Corporation (SABIC).

Advantages and Benefits of ULTEM

ULTEM is a material with the following advantages and benefits

• Heat resistant to 180-220°C
• Dimensional stability at high temperatures and in steam
• Flame retardant (UL94 V-0 certified)
• Low smoke and low toxicity during combustion
• UV resistance, weather resistance
• Chemical resistance (oils, alcohols, acids, etc.)
• High dielectric strength
• Hygiene for human body and food
• Less expensive than other super engineering plastics
• Easy to manufacture

While it has a good balance of properties including heat resistance and flame resistance, it also has the advantage of being less expensive than other super engineering plastics and easier to manufacture due to its dimensional stability.

Disadvantages and disadvantages of ULTEM

ULTEM has the following disadvantages and disadvantages

• Susceptible to organic solvents
• Low abrasion resistance

Although ULTEM has many advantages and benefits, its disadvantages and disadvantages should be noted.

Types of ULTEM

There are several types of ULTEM, each with different characteristics as follows

type	feature
ULTEM1000	Standard unfilled grade, high heat resistance, strength, and dimensional stability
ULTEM1010	Highest level of heat resistance and mechanical strength
ULTEM2100 2200 2300	Glass-reinforced grades with glass fiber content of 10%, 20%, and 30%, respectively; improved strength, stiffness, and dimensional stability at high temperatures
ULTEM5000 5100	Grades designed with the aviation industry in mind; improved flammability, smoke generation, and toxicity characteristics
ULTEM4001 4011	Grades optimized for improved processability in injection molding applications ・4001 has high heat resistance, chemical resistance, and biocompatibility ・4011 is characterized by resistance to a variety of chemicals and biocompatibility
Carbon Fiber Filled ULTEM	Strong composite material combining the light weight and strength of carbon fiber with the excellent mechanical, thermal, and chemical resistance of ULTEM.

Types of PEI other than ULTEM

In addition to ULTEM, PEI, a super engineering plastic, includes the following types

type	feature
Standard Grade	Excellent mechanical strength and heat resistance ・Performs well in temperature environments of 150°C or higher
Reinforced Grade	Glass fiber 30% blended, high stiffness and creep strength
High Reinforced Grade	PEI composites based on polyetherimide (Ultem resin) reinforced by woven glass fiber fabrics of ∙50 vol%.

Examples of scenes and products in which ULTEM is used

Scenes and products that utilize ULTEM include the following

• Aerospace industry (e.g., brackets in aircraft)
• Automotive industry (oil pumps)
• Petrochemical industry (work tools)
• Medical industry (surgical instruments)
• Consumer products (eyeglass frames, guitar picks, etc.)

Advantages of cutting ULTEM

Cutting is one of the methods used to create products and parts made of ULTEM.
The advantages of using cutting for ULTEM are explained in turn.

Reduced processing costs

Cutting has the advantage that machining can be started immediately with data and programs, without the need to fabricate dies.
Processing costs can be reduced because there are no tooling costs.

Since ULTEM is a low-cost material among super engineering plastics, it is possible to manufacture products while considering the balance between cost and quality.

Capable of manufacturing products with fine dimensions with high precision

Cutting is based on data and programs, so dimensions can be adjusted in microns.
Therefore, ULTEM is highly compatible with applications that require high precision and dimensional control, such as automotive and aerospace products.

Can be processed into a wide range of shapes

Cutting can be performed without limiting the width as long as the cutting machine can handle it.
Furthermore, since machining proceeds based on data and programs, it is also possible to process complex shapes.

ULTEM-based fabrication of parts for the aerospace industry and surgical supplies for the medical field, which require detailed parts and complex shapes, can also be realized with cutting.

Points to be noted in ULTEM cutting process

PEI, including ULTEM, has a high notch sensitivity and is prone to stress concentration when cutting corners.
Therefore, taking corner radii during machining to distribute stress will prevent cracking and chipping during cutting.

If it is difficult to obtain a corner radius depending on the part, it is effective to reduce the depth of cut and feed rate as much as possible.

Note that when bonding, physical bonding methods are used rather than welding methods such as acrylic or PVC, so bonding may be lax.

How to choose a contractor for ULTEM cutting

ULTEM's cutting process varies in terms of workmanship, cost, and delivery time, depending on the vendor you request.
Here are some tips on how to choose a vendor that you should also keep in mind when considering ULTEM's cutting services.

Do you have experience in ULTEM cutting?

Among the cutting operations, be sure to select a supplier that has extensive experience in fabricating parts and products using ULTEM.

A contractor with extensive ULTEM cutting experience can adjust the appropriate machining speed, install corner Rs, and select tools when cutting ULTEM.
ULTEM cutting, which requires a high degree of dimensional control and precision, can be expected to produce satisfactory results.

Can other materials and processing methods be considered?

Please also check with us about our experience in machining materials other than ULTEM, as well as our experience in machining other than cutting.
Depending on the part or product you wish to fabricate, there may be more appropriate materials or processing methods.

A supplier with more experience in other materials and processing methods will not only be a better choice, but will also have the advantage of being able to request the manufacture of products other than ULTEM as well.

Can the processing cost and delivery date be met or exceeded?

ULTEM processing costs and turnaround times vary depending on the vendor you request.

Even for contractors with extensive experience, there is no possibility of problems such as late delivery or cost overruns.
Once you have found a potential vendor, request a quote to confirm costs and also to understand specific delivery dates.

ULTEM is a material used in 3D printing

ULTEM is also a material used in processing with 3D printers.

Using ULTEM in 3D printing not only allows for machining without the need for tooling, but also results in very little wasted material.
This makes ULTEM even more cost-effective.

Also, if 3D printers are used for weight reduction, it is possible to reduce weight by machining complex shapes that are difficult to achieve with conventional machining methods.

It will further take advantage of the lightweight nature of ULTEM.

Summary

The overview of ULTEM, its merits and demerits, as well as cautions for ULTEM cutting and machining were explained.

ULTEM is a component with low cost and well-balanced performance among super engineering plastics.
Selecting and requesting a contractor with high technical skills and a proven track record will lead to satisfactory processing.

If you are considering manufacturing parts using ULTEM, please contact us!Taiga."Please make use of the following
Taiga is a free service that allows you to consult with experienced contractors.

We can efficiently proceed with the development of difficult or new parts, small-lot production, prototyping, and mass production while keeping costs low.

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