PPSU-Solvay Radel R-5100
Enabling flawless visual color-coding for surgical sizing trials while maintaining exceptional resistance to repeated autoclaving and high impact forces requires an advanced biocompatible polymer, which Syensqo’s Radel R-5100 (formerly Solvay) delivers through its unreinforced, opaque, pre-colored polyphenylsulfone (PPSU) matrix. Certified to USP Class VI, ISO 10993, and FAA FAR 25.853a flammability standards, this tough thermoplastic resists environmental stress cracking under aggressive clinical detergents. Jucheng Precision, under strict ISO 13485 and IATF 16949 certified frameworks, specializes in micro-molding Radel R-5100 in dedicated ISO Class 7/8 cleanrooms. Utilizing 5-axis CNC-machined S136 stainless steel molds, we control internal stresses and ensure zero particulate contamination, delivering high-purity medical assemblies verified by Zeiss CMM.
Radel R-5100 Opaque Medical Pre-Colors & Flame Compliance
Radel® R-5100 is an unreinforced amorphous Polyphenylsulfone (PPSU) resin, certified to deliver outstanding impact strength, low smoke density, and multiple medical-grade pre-colors under ISO/ASTM standards:
| Material & Flammability Class | Radel R-5100 Standard Metric | Molding & Assembly Advantage |
|---|---|---|
| Certified Pre-Colors | Opaque Blue, Grey, Red, Bone & Black | Provides permanent and biocompatible color-coding options, allowing surgeons to identify exact instrument sizes quickly during dynamic trials. |
| FAA FAR Flammability | FAR 25.853a Compliance (60-sec vertical burn) | Inherently flame retardant without modifiers, complying with aircraft safety standards for low smoke toxicity and OSU heat release. |
| Impact Toughness | Notched Izod Impact 690 J/m (ASTM D256) | Delivers virtual indestructibility and structural toughness under repeated drops or dynamic impacts. |
Structural Process & Color-Coding Configurations for Radel R-5100
With its stable melt viscosity and amorphous consistency, Radel R-5100 processes reliably inside high-heat systems:
| Phương pháp xử lý | Khả năng tương thích Đúc & Chi tiết Vận hành |
|---|---|
| Color-Coded Surgical Sizing Trials | Excellent. Molded within our ISO Class 7/8 cleanrooms using pristine colored pellets to prevent cross-color contamination in surgical trials and spacer blocks. |
| High-Impact Orthopedic Instrument Handles | Excellent. High impact strength and exceptional chemical resistance prevent stress cracking under continuous autoclaving and dynamic surgical load. |
| Structural Aviation Enclosures | Good. High specific modulus and low outgassing enable lightweight aircraft cabin structures complying with strict FAR fire and smoke safety. |
PPSU-Solvay Radel R-5100 Cleanroom Tooling & Processing Guide
Molding an amorphous high-performance colored blend like Radel R-5100 requires strict thermal boundaries and full-contamination prevention protocols:
Đúc Phun trong Phòng sạch ISO Class 7/8
Medical-grade colored resins must be protected from any airborne particulates or dust. Jucheng operates dedicated injection molding machines inside fully enclosed, positive-pressure ISO Class 7/8 cleanrooms. Raw material feeding, plastication, and robot part-ejection are completely automated and isolated.
Khuôn S136 đánh bóng gương (Bảo toàn độ tinh khiết)
Để ngăn ngừa kích ứng mô do độ nhám bề mặt vi mô, chúng tôi chế tạo khuôn bằng thép không gỉ S136 hàm lượng crom cao. Các khoang được đánh bóng gương đến mức cao bằng bột kim cương sạch, đảm bảo bề mặt chi tiết tương thích sinh học không xốp, không có vết kéo nhả động.
Pressurized Oil Mold Temperature Control
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.
Desiccant Pre-Drying Protocol
PPSU 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.
Key Application Fields for PPSU-Solvay Radel R-5100
- Medical & Dental Sizing Trials (ISO 13485): Autoclavable colored orthopedic sizing trials, surgical instrument handles, implant alignment guides, and dental spacer blocks.
- Aviation & Passenger Transit: Aircraft cabin passenger service units, structural window bezels, commercial ventilation duct fittings, and heavy-duty connectors.
- Plumbing & Fluid Delivery: High-temperature residential water manifold fittings, boiler water mixing connectors, chemical-resistant fluid couplers, and pump impellers.
Properties
| Mật độ | 1.3 g/cm³ |
| Melt Mass-Flow Rate (MFR) (365°C/5.0kg) | 14.0 - 20.0 g/10 min |
| Mô đun kéo | 2,410 MPa |
| Độ bền kéo tại điểm chảy dẻo | 69.6 MPa |
| Độ giãn dài khi đứt | 60 % |
| Mô đun uốn | 2,410 MPa |
| Độ bền uốn | 91 MPa |
| Izod Notched Impact Strength (1/8, 23°C) | 690 J/m |
| Điểm hóa mềm Vicat | 218 °C |
| Nhiệt độ biến dạng nhiệt (HDT @ 1.82 MPa) | 207 °C |
| Độ co rút khuôn tuyến tính | 0.7 % |
| Độ bền điện môi | 18 kV/mm |
| Volume Resistivity | 1.0E+16 Ohm-cm |
| Kích thước chi tiết tối đa (Giới hạn phòng sạch) | 600 x 400 mm |
| Kích thước chi tiết tối thiểu | 1 x 1 mm |