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MetalKeen specializes in CNC machining of PEEK parts for the medical device and electronics industries. We machine virgin PEEK, glass-filled, carbon-filled, and implant-grade PEEK-OPTIMA into precision components including surgical instrument handles, implant prototypes, semiconductor test sockets, and high-voltage insulators. With tight tolerance control, annealing expertise, and ISO 13485–compliant processes, our PEEK components meet the demanding requirements of biocompatibility, chemical resistance, and dimensional stability.
PEEK (Polyether Ether Ketone) is a high-performance thermoplastic polymer belonging to the polyaryletherketone (PAEK) family. It offers a unique combination of properties that make it ideal for critical medical and electronic applications:
Table
Property | PEEK Value | Benefit for Medical / Electronic |
|---|---|---|
Continuous Use Temperature | 260°C (500°F) | Sterilization compatibility (autoclave, gamma, EtO); high-temp electronics |
Tensile Strength | 90–100 MPa (virgin) | Structural integrity for surgical tools and load-bearing components |
Modulus of Elasticity | 3.6 GPa (similar to bone) | Bone-like stiffness for orthopedic implants; reduces stress shielding |
Chemical Resistance | Excellent | Withstands disinfectants, solvents, acids, and process chemistries |
Biocompatibility — ISO 10993 | USP Class VI; cytotoxicity negative | Safe for long-term implantation and patient contact |
Dielectric Strength | 19 kV/mm | Excellent electrical insulation for connectors and insulators |
Radiolucency | X-ray transparent | Allows clear post-operative imaging without artifact |
Low Outgassing — NASA ASTM E595 | TML < 1%; CVCM < 0.10% | Suitable for vacuum and space electronic applications |
PEEK vs. Metals and Other Plastics:
Table
Material | Weight | Biocompatibility | Temp Limit | Machinability | Best For |
|---|---|---|---|---|---|
PEEK | Light | Excellent | 260°C | Moderate (expertise required) | Implants, insulators, high-heat parts |
Titanium | Heavy | Excellent | >1000°C | Good | Permanent implants; high load |
Stainless 316L | Heavy | Good | 800°C | Excellent | Surgical instruments; non-implant |
PTFE (Teflon) | Light | Good | 260°C | Good | Seals; bearings; low friction |
PEI (Ultem) | Light | Good | 170°C | Excellent | Lower-temp electronics; housings |
Delrin (POM) | Light | Limited | 100°C | Excellent | Gears; bushings; non-implant |
MetalKeen machines the full range of PEEK grades to match your application requirements:
Table
Grade | Composition | Key Properties | Best Application |
|---|---|---|---|
PEEK 450G / 150G — Virgin unfilled | 100% PEEK resin | Highest elongation; best purity; excellent polishability | Medical implants; food contact; optical components |
PEEK 450GL30 — 30% glass fiber | PEEK + 30% short glass fibers | 2× stiffness; higher creep resistance; lower thermal expansion | Structural electronic housings; high-strength medical tools |
PEEK 450CA30 — 30% carbon fiber | PEEK + 30% short carbon fibers | 3× stiffness; highest strength; wear resistant; conductive | Bearing surfaces; surgical guides; EMI-shielded components |
PEEK 450FC30 — Graphite/PTFE filled | PEEK + graphite + PTFE | Lowest friction coefficient; self-lubricating; wear resistant | Bushings; seals; sliding medical components |
PEEK-OPTIMA — Medical implant grade | Ultra-high purity PEEK | Biocompatible per ISO 10993; radiolucent; bone-like modulus | Spinal implants; dental abutments; orthopedic prototypes |
PEEK-CLASSIX — Medical device grade | High-purity PEEK | USP Class VI; sterilizable; no animal derivatives | Surgical instrument handles; diagnostic device housings |
Table
Component | Application | Machining Notes |
|---|---|---|
Surgical Instrument Handles — Scalpel, forceps, retractor grips | Ergonomic, lightweight, sterilizable handles | Complex 3D contours; soft-touch overmold interfaces |
Implant Prototypes — Spinal cages, dental abutments, cranial plates | Pre-clinical and clinical trial devices | Implant-grade PEEK-OPTIMA; tight tolerance; polished surfaces |
Medical Device Housings — Pump housings, sensor enclosures, valve bodies | Protect electronics and fluids from contamination | Multi-axis milling; threaded inserts; sealing surfaces |
Diagnostic Consumables — Microfluidic manifolds, cartridge components | Lab-on-chip and IVD device parts | Micro-milling features; tight channel tolerances |
Surgical Guides & Fixtures — Drill guides, cutting blocks, alignment jigs | Patient-specific orthopedic surgery | Carbon-filled PEEK for rigidity; sterilizable |
Endoscope Components — Light guide holders, instrument channels | High-temp sterilization compatibility | Thin-wall machining; optical bore precision |
Table
Component | Application | Machining Notes |
|---|---|---|
Semiconductor Test Sockets — IC test sockets, burn-in sockets | High-temp testing of chips and packages | Micro-precision holes; tight flatness; wear-resistant grades |
Wafer Handling Components — End effectors, wafer chucks, carriers | Cleanroom wafer transport and processing | Virgin PEEK; minimal particle generation; electrostatic control |
High-Voltage Insulators — Connector bodies, standoffs, bushings | Electrical isolation in power electronics | Tight tolerance; smooth surfaces; tracking resistance |
RF / Microwave Components — Insulators, spacers, antenna parts | Low-loss dielectric for high-frequency signals | Precision thickness; stable dielectric constant |
Electronic Enclosures — Sensor housings, relay bodies, switch components | Protect sensitive electronics from heat and chemicals | Thin-wall milling; EMI shielding options (carbon-filled) |
Battery & EV Components — Cell spacers, connector insulators, busbar supports | High-voltage isolation in electric vehicles | Flame-retardant grades; high creep resistance |
Table
Capability | Specification | Notes for PEEK |
|---|---|---|
CNC Turning | Diameter: 2 mm – 300 mm; Length: 200 mm | Sharp carbide or diamond-coated tools; controlled heat |
CNC Milling — 3, 4, 5-axis | Work envelope: 600 × 400 × 300 mm | Cryogenic or air-blast cooling to prevent melting |
Swiss-Type Turning | Diameter: 0.8 mm – 32 mm | Ideal for micro medical implants and electronic pins |
Wire EDM | Tolerance: ±0.005 mm | No cutting force; perfect for thin-wall PEEK parts |
Surface Grinding — Flat and cylindrical | Tolerance: ±0.01 mm; Ra 0.2 μm | Achieves precision flatness for test sockets |
Tolerance Standard | ISO 2768-f (fine) or ±0.02 mm | Tighter tolerances available for critical fits |
Minimum Feature Size | 0.1 mm walls; 0.3 mm holes | Dependent on PEEK grade and part geometry |
PEEK is a high-performance polymer that requires specialized machining knowledge. MetalKeen's process controls ensure defect-free parts:
Table
Challenge | MetalKeen Solution | Benefit |
|---|---|---|
Heat Buildup — PEEK softens at ~143°C (Tg) | Cryogenic air cooling; sharp carbide tools; conservative speeds/feeds | Prevents melting, burring, and dimensional distortion |
Internal Stress / Warping — From machining and residual molding stress | Pre-machining annealing; post-machining stress relief | Maintains flatness and tolerance after machining |
Fiber Exposure — Glass/carbon fibers fray at cut edges | Optimized tool geometry; controlled chip load; deburring protocols | Clean edges; no fiber contamination in medical use |
Surface Finish — PEEK can machine with streaks or chatter | Rigid fixturing; vibration-dampened setups; light finishing passes | Aesthetic and functional surfaces; Ra 0.4 μm achievable |
Hygroscopic Absorption — PEEK absorbs moisture | Pre-drying at 150°C; climate-controlled machining; sealed packaging | Prevents dimensional change and bubble formation |
Crystallinity Control — Amorphous vs. crystalline PEEK behave differently | Material certification; annealing protocols matched to grade | Predictable mechanical properties |
Table
Finish / Treatment | Process | Result | Application |
|---|---|---|---|
As-Machined — Fine machining pass | Controlled feeds and speeds | Ra 0.8–1.6 μm; visible tool marks acceptable | Functional electronic components; prototypes |
Precision Polishing — Manual or automated | Progressive abrasive polishing | Ra 0.2–0.4 μm; glossy surface | Medical implants; aesthetic handles; sealing surfaces |
Vapor Polishing — Solvent vapor exposure | Controlled solvent vapor smoothing | Transparent-like finish; reduced surface porosity | Optical PEEK parts; microfluidic channels |
Coating / Overmolding — Silicone or thermoplastic elastomer | Secondary molding or adhesive bonding | Soft-touch grip; color coding; sealing | Surgical instrument handles; ergonomic grips |
Laser Marking — UV or fiber laser | Permanent, non-contact marking | UDIs, logos, serial numbers; no particle contamination | Medical devices; traceability requirements |
Sterilization Validation — Gamma, EtO, autoclave | Coordinated with customer protocol | Confirms material stability post-sterilization | Implant and surgical device qualification |
Table
Test / Inspection | Method | Standard | Purpose |
|---|---|---|---|
Dimensional Inspection — CMM | 3D coordinate measurement | ISO 9013 | Verify all critical dimensions and GD&T |
Surface Roughness — Profilometer | Contact stylus | ISO 4287 | Confirm Ra for sealing and sliding surfaces |
Material Certification — COA / MTR | Supplier certificate of analysis | ISO 9001 | Verify PEEK grade and batch purity |
Biocompatibility — Customer-supplied | ISO 10993 testing (cytotoxicity, sensitization) | ISO 10993 | Validate medical-grade PEEK for patient contact |
Visual Inspection — Magnification | 10×–40× stereo microscope | ISO 13485 | Detect machining defects, fiber exposure, cracks |
Cleanliness — Particle / residue | Ultrasonic cleaning; particle count | ISO 14644 / Customer spec | Ensure particle-free for cleanroom / medical use |
Compliance Standards:
ISO 13485 — Medical device quality management system
ISO 9001 — General quality management
ISO 10993 — Biocompatibility evaluation (customer-coordinated testing)
FDA 21 CFR — Material and process traceability for US medical market
✅ Medical & Electronic Focus — Dedicated expertise in both industries' unique requirements
✅ Full PEEK Portfolio — Virgin, glass-filled, carbon-filled, and implant-grade PEEK-OPTIMA
✅ Thermal Management — Cryogenic cooling and annealing protocols prevent PEEK degradation
✅ Micro-Precision — Swiss turning and 5-axis milling for complex, tight-tolerance parts
✅ Biocompatible Processes — ISO 13485–controlled environment; material traceability
✅ Surface Finishing — Polishing, vapor smoothing, laser marking, and coating capabilities
✅ Prototype to Production — 1-piece prototypes to 10,000+ piece annual volumes
Q1: What is PEEK, and why is it used for medical and electronic parts? PEEK (Polyether Ether Ketone) is a high-performance engineering thermoplastic with a continuous use temperature of 260°C, excellent chemical resistance, and superior mechanical strength compared to most plastics. For medical applications, PEEK is biocompatible (ISO 10993), radiolucent, and has a bone-like elastic modulus—making it ideal for implants and surgical instruments. For electronics, PEEK offers high dielectric strength, low outgassing, and high-temperature stability—critical for semiconductor test sockets, insulators, and wafer handling components.
Q2: What is the difference between virgin PEEK and filled PEEK grades? Virgin PEEK (450G/150G) is 100% pure PEEK resin, offering the highest elongation, best purity, and finest surface finish—preferred for medical implants and optical parts. Glass-filled PEEK (450GL30) contains 30% glass fibers, doubling stiffness and reducing thermal expansion for structural electronic housings. Carbon-filled PEEK (450CA30) contains 30% carbon fibers, tripling stiffness and adding wear resistance and conductivity for bearings and EMI-shielded parts. We help you select the optimal grade based on load, temperature, and regulatory requirements.
Q3: Can PEEK parts be sterilized, and which methods are compatible? Yes. PEEK is compatible with all major sterilization methods: steam autoclaving (134°C, 2 bar, 18-minute cycles—tested to 1000+ cycles), gamma irradiation (25–50 kGy typical dose), and ethylene oxide (EtO) gas. PEEK is not compatible with dry heat sterilization above 300°C or prolonged UV exposure. For implant-grade PEEK-OPTIMA, we provide material certificates and can coordinate biocompatibility testing per ISO 10993.
Q4: What tolerances can you hold when CNC machining PEEK? Our standard machining tolerance for PEEK is ±0.02 mm (ISO 2768-f), with ±0.01 mm achievable for critical features such as test socket pin holes and implant mating surfaces. For micro medical components, our Swiss-type lathes hold ±0.005 mm. Tighter tolerances than ±0.005 mm are generally not recommended for PEEK due to its thermal expansion coefficient (≈50 ppm/°C), which can cause dimensional shift with temperature changes.
Q5: Why does PEEK require annealing before and after machining? PEEK parts—especially thick sections or filled grades—can contain residual molding stresses that cause warping during machining. Pre-machining annealing at 200–250°C relieves these stresses, ensuring the blank is dimensionally stable before cutting. Post-machining annealing may be applied to relieve cutting-induced stresses in complex geometries. MetalKeen performs annealing in controlled ovens with slow ramp rates to prevent crystallinity changes that could affect mechanical properties.
Q6: Can you machine implant-grade PEEK-OPTIMA for medical device development? Yes. We machine PEEK-OPTIMA (Invibio medical-grade PEEK) for spinal implant prototypes, dental abutments, cranial plates, and orthopedic trial implants. Our ISO 13485–controlled processes ensure full material traceability, batch records, and clean handling to prevent cross-contamination. We can support your design validation, clinical trial, and regulatory submission with documentation packages including material certificates and dimensional inspection reports.
Q7: What is the typical lead time for custom PEEK parts? Prototype quantities (1–10 pieces) typically ship in 1–2 weeks depending on geometry complexity. Volume production (100–5,000 pieces) requires 3–5 weeks including fixture preparation. Implant-grade PEEK-OPTIMA parts may require additional 1 week for material procurement from authorized distributors. Expedited prototyping is available for urgent medical device development schedules.
