A well-known Belgian manufacturer of specialty engineering plastics focuses on the R&D and production of high-performance polymers. One of its core products, polyether ether ketone (PEEK)powder, is widely used in aerospace, medical devices, automotive, and electronics industries due to its outstanding high-temperature resistance, chemical stability, high mechanical strength, and biocompatibility.
In the customer’s production process, polymerized PEEK granules need to be finely ground to produce high-quality Polyether Ether Ketone (PEEK) powder with uniform particle size and good flowability, suitable for precision injection molding, powder coating, and advanced applications such as 3D printing. Especially for medical implants and aerospace components, extremely stringent requirements are imposed on particle size distribution and purity. The customer’s existing milling equipment could no longer meet the increasing capacity demand or the pursuit of finer particle sizes.
Challenges
- Extremely high precision requirements:
The target product requires a D50 of approximately 25μm with a narrow particle size distribution to ensure stability in downstream processes and consistent product performance. - Material characteristics:
PEEK is a high-toughness thermoplastic with a high melting point (around 343°C). Conventional mechanical grinding easily generates excessive heat, leading to material softening, agglomeration, or even degradation, which negatively affects product quality and equipment efficiency. - Product purity:
As a high-end engineering material, Polyether Ether Ketone (PEEK) powder must be completely free from metal or other contaminant impurities. - Energy consumption and efficiency:
The customer aimed to improve productivity while reducing energy consumption, without compromising product quality.
Epic Powder Jet Mill Solution
Based on the specific characteristics of PEEK (high toughness, thermal sensitivity, and tendency to generate static electricity), Epic Powder recommended an advanced Jet Mill system. This technology utilizes high-velocity airflow to induce particle-to-particle collisions for size reduction, avoiding the frictional heat associated with mechanical milling. As a result, material thermal degradation is effectively prevented while achieving a narrow particle size distribution and a uniform, near-spherical particle morphology.
- Main equipment:
Epic Powder jet mill equipped with a high-precision classifier wheel, pulse dust collection system, and a closed-loop circulation design. - Auxiliary systems:
Pre-cooling feeding unit and anti-static surface treatment module to ensure stable and safe operation. - Process optimization:
Precise particle size control achieved by adjusting air pressure, feed rate, and classifier speed. The entire system operates under full negative pressure, ensuring clean and environmentally friendly production.
In addition, the system is suitable not only for grinding Polyether Ether Ketone (PEEK) granules but also for subsequent surface modification processes (such as silane coupling agent coating), further improving powder flowability and dispersion.
Key Data and Results
| Category | Description |
|---|---|
| Particle Size Distribution | D50 = 25.6 μm; D97 < 50 μm; narrow particle size distribution (Span < 1.5); uniform, near-spherical particle morphology |
| Powder Properties | Excellent flowability (angle of repose <40°); no agglomeration; high whiteness; purity maintained at raw material level; moderate specific surface area |
| Application Performance | Suitable for powder coating, precision injection molding, and Selective Laser Sintering (SLS) 3D printing |
| Throughput & Energy Consumption | Single-line capacity of 50-100kg/h(depending on feedstock); significantly lower energy consumption compared to the customer’s original equipment |
| Quality Stability & Compliance | Minimal batch-to-batch variation; fully compliant withEU REACH regulations and medical-grade application requirements |