PEI-SABIC Ultem 1010
Filling ultra-thin, highly complex flow paths in high-voltage avionics and medical cassettes while maintaining 110 MPa yield strength requires an optimized high-flow super-polymer, which SABIC’s Ultem 1010 delivers through its unreinforced, high-viscosity amorphous polyetherimide matrix with improved melt rheology. Featuring an elevated glass transition temperature (Tg) of 217°C and a density of 1.27 g/cm³, this aerospace FAR 25.853 compliant grade achieves a V-0 flammability rating at 0.4mm. Jucheng Precision, under ISO 9001 and IATF 16949 frameworks, specializes in molding Ultem 1010. Utilizing 5-axis CNC-machined conformal cooling toolings, we manage its isotropic shrinkage (0.5%-0.7%) to deliver zero-defect parts verified by Zeiss CMM.
SABIC Ultem 1010 Rheological & Tensile Integrity Profile
SABIC™ Ultem™ 1010 is an unreinforced amorphous Polyetherimide (PEI) resin, certified to deliver improved flow, exceptional chemical resistance, and high-heat mechanical stiffness under ISO/ASTM standards:
| Physical & Strength Parameter | SABIC Ultem 1010 Value | Molding & End-Use Advantage |
|---|---|---|
| Melt Flow Rate | MVR 13 cm³/10min (MVR 25 @ 360°C) | Improved melt rheology allows effortless cavity filling on thin-walled connectors and multi-cavity electronic micro-frames. |
| Structural Ductility | Tensile Strain at Break 50 – 60% | Exhibits exceptional elongation and yield toughness among unreinforced PEI resins, preventing brittle failure in snap-fit bobbins. |
| Inherent Flame Retardancy | UL 94 V-0 (at 0.40 mm) & FAA Compliant | Meets aerospace FAR 25.853 low smoke toxicity and OSU heat release requirements, highly certified for commercial cabin interiors. |
Thin-Walled Process Configurations for High-Flow Ultem 1010
With its high-flow melt performance and amorphous stability, Ultem 1010 processes consistently inside tight mold cavities:
| Molding Technology Class | Process Compatibility & Operational Details |
|---|---|
| Thin-Walled Aviation Connectors | Excellent. The primary process for Ultem 1010. Perfect for sub-millimeter aerospace connector blocks, cable guide clips, and fuel sensor shells. |
| High-Flow Medical Diagnostics | Excellent. Run inside our certified ISO Class 7/8 cleanrooms to mold highly complex in-vitro diagnostic cassettes, clear wells, and cuvettes. |
| Multi-Pin Electronic Terminals | Excellent. Stable flow behaviors at low melt temperatures reduce energy consumption and shorten cycle times on multi-cavity terminal runs. |
PEI-SABIC Ultem 1010 High-Flow Mold Design Blueprint
Molding an improved-flow, amorphous resin like Ultem 1010 requires tight parting line fitment to prevent flashing and thorough pre-drying to protect tensile strength:
Micron-Level Flash Control (Tooling Precision)
Because Ultem 1010 has improved flow capabilities (MVR 13 cm³/10min), molten resin can seep easily into minor mold gaps, causing parting line flash. Jucheng’s tooling division uses 5-axis CNC machines to achieve micro-tolerances, keeping mold parting clearances strictly within 0.005mm on premium S136 stainless steel mold cavity blocks.
Pressurized Oil Mold Temperature Matrix
Pressurized oil heaters are utilized to maintain mold temperatures at 140°C–180°C (284°F to 356°F). Maintaining high mold temperatures is critical to minimize molded-in stress, optimize surface gloss, and completely prevent weld-line stress cracking near intricate snap-fits.
Extended Desiccant Pre-Drying Protocol
PEI is highly hygroscopic. Moisture causes cosmetic splay, bubbles, and loss of transparent optical quality. We dry raw material in desiccant hopper dryers at 150°C (302°F) for 4 hours to keep moisture levels below 0.02% before molding, protecting dynamic mechanical tensile bonds.
Low Amorphous Isotropic Shrinkage
Like standard PEI, Ultem 1010 exhibits low and highly uniform shrinkage (0.50% to 0.70%). We machine balanced, conformal cooling circuits directly into core blocks to speed up heat dissipation, further reducing cycle times and preventing thermal warpage.
Key Application Fields for PEI-SABIC Ultem 1010
- Aviation Cabin Interiors & Systems: High-safety passenger service trays, environmental control duct fittings, commercial cabin lighting covers, and structural avionic cable harness clamps.
- Electrical, Office & Electronics: High-temperature burn-in test sockets, terminal blocks, electrical switches, heavy-duty coil bobbins, and printer fuser units.
- Medical Diagnostics & Consumables (ISO 13485): Clear microfluidic diagnostic chips, laboratory cuvettes, sample vials, medical caps, and pharmaceutical blister containers.
Properties
| Density | 1.27 g/cm³ |
| Melt Volume-Flow Rate (MVR) (340°C/5.0kg) | 13 cm³/10min |
| Melt Volume-Flow Rate (MVR) (360°C/5.0kg) | 25 cm³/10min |
| Tensile Modulus | 3,200 MPa |
| Tensile Stress at Yield | 110 MPa |
| Tensile Stress at Break | 85.0 MPa |
| Tensile Strain at Break | 60 % |
| Flexural Modulus | 3,300 MPa |
| Flexural Strength | 160 MPa |
| Notched Izod Impact Strength (23°C) | 5.0 kJ/m² |
| Glass Transition Temperature (Tg) | 217 °C |
| Vicat Softening Point (B/50) | 211 °C |
| Heat Deflection Temperature (HDT @ 1.80 MPa) | 190 °C |
| Linear Mold Shrinkage | 0.50 - 0.70 % |
| Flammability Rating (0.41mm) | UL 94 V-0 Class |
| Maximum Part Size | 800 x 600 mm |
| Minimum Part Size (Micro Connector limit) | 1 x 1 mm |