PEI resin

Third-party test results have validated multiple sterilization capabilities of Sabic Innovative Plastics’ Ultem HU1004 polyetherimide (PEI) resin. The high-performance resin has been tested for use with the STERRAD NX low-temperature hydrogen peroxide gas plasma sterilization. The data revealed that the resin has significant performance and aesthetic advantages—in particular, ductility and color stability–over materials such as polyphenylsulfone (PPSU).

According to the company, Ultem HU1004 resin meets critical industry sterilization demands, including higher-temperature autoclaving, ethylene oxide, and gamma radiation for enhanced safety. It can also be used for low-temperature sterilization processes to protect delicate electronic devices. The resins have been used in applications such as surgical devices (tissue stabilizers, skin staplers, and laparoscopic device handles) and in medical equipment such as anesthesia machines and orthopedic devices.

Sabic commissioned SPS Medical, an independent testing lab located in Rush, NY, to validate the mechanical properties and degree of color shift for Ultem HU1004 resin after exposure to the STERRAD NX method. SPS exposed samples of Ultem resin and PPSU to STERRAD NX sterilization in increments of 50 cycles up to 300.

The findings demonstrate that Ultem HU1004 resin provides superior color stability compared with PPSU. According to Sabic, PPSU showed a color shift up to 10 times greater than Ultem HU1004 resin, becoming significantly yellowed after only 100 STERRAD NX cycles. Ultem resin also delivered superior mechanical properties, including retention of mass and impact performance, compared with PPSU.

Following are key findings from the testing:

• Ultem HU1004 resin lost less than a total of 0.5% of its weight after 150 and 300 STERRAD NX cycles
• Ultem HU1004 resin retained >99% of its tensile strength at 150 cycles and 98% at 300 cycles. For tensile elongation at break, the Ultem resin retained 94% of performance at 150 cycles and 77% at 300 cycles.
• Testing, conducted by SABIC Innovative Plastics on autoclave sterilization, showed that even after 2500 autoclave cycles at 134°C, Ultem HU1004 resin retained ductility, stiffness and strength.

Sabic Innovative Plastics, Pittsfield, MA, (413)448-7110, www.info.hotims.com/36190-500

PEAK stereolithography material

A PEAK material that withstands harsh environments is suitable for rapid prototyping. Quickparts’ Accura PEAK SLA material is an advanced stereolithography resin designed for optimal performance, accuracy, and stability during prolonged exposure to elevated temperatures and humidity. It produces rigid and stable parts that can withstand adverse environments. According to the company, it is an ideal choice for parts requiring high thermal and moisture resistance, and it provides outstanding stiffness for demanding applications.

The company says the PEAK resin is an excellent option for customers looking for a rigid, high-temp material to use for rapid prototyping. Quickparts provides custom manufacturing services for engineers and designers to create plastic and metal parts using 3D CAD files. Services include rapid prototyping (SLA, SLS,FDM, PolyJet), machined plastic prototypes, cast urethane parts, injection molding, sheet metal parts, CNC machined parts, and metal castings.

Quickparts, Atlanta, (770) 901-3200), http://www.info.hotims.com/36190-501

Non-lead radiation protection

A radiation shielding compound reduces environmental impact, eliminates machining, and provides the same radiation protection as lead. PolyOne Corp has worked together with Siemens Healthcare to develop non-lead radiation shielding components for Siemens’ newest line of CT (computed tomography) scanners.

As a result of the close collaboration among PolyOne, Siemens, and Reiter-HG Geiger, Siemens was able to design and produce components with radiation shielding performance equal to lead while eliminating machining and reducing shielding costs compared with traditional machined metal and lead parts.

The RoHS-compliant shielding compound provided reduced system costs and offered radiation-shielding performance that was equivalent to lead. Siemens Healthcare opted for a non-lead solution in preparation for a potential RoHS regulatory ban on lead. Siemens team sought an ecoconscious replacement that would effectively shield x-rays up to 140keV while offering additional manufacturing benefits.

To protect sensitive electronic components from degradation due to x-ray exposure during a CT scan, shielding elements are necessary. Traditionally, designs have required parts produced by machining or casting lead. Those lead-based components necessitated a great deal of care in handling and required assembly using hot cure adhesives. For a replacement, the team sought an injection moldable material having equivalent radiation shielding performance as compared to lead and providing uniform shielding with no hot spots.

Working together with Siemens and Reiter-HG Geiger, PolyOne’s technical team enabled the switch from lead with new material solutions based on a high-density, metallic filled material. The highly filled polymer, based on PolyOne’s Gravi-Tech technology was selected. The material blocked radiation at levels equal to those of pure lead. Furthermore, excellent dispersion of the metallic filler avoided hot spots where radiation could leak out.

PolyOne, Avon Lake, OH, (866) 765-9663, http://www.info.hotims.com/36190-503

UV elastomer

A fast-cure, low temperature silicone elastomer can be cured on demand by exposure to UV light. Addisil UV 60 EX elastomer is said to be an excellent candidate for medical applications where both lower temperatures during the manufacturing process and typical silicone rubber physical properties are required. According to the company, a particularly promising area is combination products where silicone rubber parts are combined with heat-sensitive materials. In these types of applications, the elastomer’s UV cure technology can enable medical device manufacturers to consider a much broader range of ingredients.

The elastomer offers minimal shrinkage, reduced air entrapment, and shorter cure times. It also offers potential for cost savings because it can be extruded without heat. It can be used with existing silicone extrusion equipment and common UV light curing systems.

Momentive Performance Materials, Columbus, OH, (800) 295-2392, www.info.hotims.com/36190-504

Static-dissipative ABS

A static dissipative ABS material is suitable for items sensitive to electrostatic charge. Stratasys’ ABS-ESD7 is a new material for use by Fortus additive manufacturing systems. The material has static dissipative properties for applications where a static charge can damage products, impair performance, or cause an explosion.

Unlike most thermoplastics, ABS-ESD7 is said to prevent a buildup of static electricity; therefore, it can’t produce a static shock. Besides eliminating static shock, the ESD material eliminates another common static electricity problem: the attraction and buildup of particulate, such as dust or powders, which can degrade product performance.

According to the company, ABS-ESD7 is also beneficial when designing products that avoid attracting atomized liquid, such as medicine inhalers, which must deliver the entire drug dose to the patient and not leave mist clinging to inhaler’s internal surfaces.

ABS-ESD7 will run on Fortus 400mc and Fortus 900mc FDM systems. It is comparable in operation to its non-ESD counterpart, ABS-M30, from Stratasys. All mechanical properties of ABS-ESD7 are within 5% of the ratings for ABS-M30.

Stratasys, Minneapolis, (888) 480-3548, http://www.info.hotims.com/36190-502