Ultem CNC Machining Services

TOP Precision (TOPS) has the top CNC Ultem machining services and delivers high-performance and long-lasting plastic components for application that requires durability. Our team of engineers and machinists has vast experience dealing with high-end thermoplastics such as Ultem (PEI), which has outstanding mechanical, thermal, and chemical properties.

  • Precision Tolerances up to ±0.01 mm for the tight and complex shapes
  • High Heat Resistance for components that are subjected to thermal shock
  • Optimum tooling and speeds for high Machinability
  • From CAD to QA and assembly – Full-Service Workflow

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    TOPS provides fully customised solutions – from rapid prototyping to high-volume production. We help you deliver precision, consistency, and functionality in all machined Ultem parts! Besides this, we play a vital role in the aerospace, medical devices, electronics, and industrial automation industries.

    What is Ultem

    What is Ultem?

    Ultem is a technical name for Polyetherimide (PEI), which is a high-performance thermoplastic, patented by SABIC. It has combined immaculate mechanical strength, resistance to high temperatures, and insulation from electricity in a single material. Ultem is often preferred over metals and plastic of the lower grade in aerospace, medical, and electronic products.

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      How Ultem CNC Machining Works

      Ultem CNC machining is a step-by-step process consisting of painstaking, streamlined procedures meant to keep the integrity of this high-performance thermoplastic intact:

       

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        How Ultem CNC Machining Works

        Design & Programming

        Your CAD model is translated to optimized CNC code, taking into consideration thermal sensitivity and mechanical characteristics of Ultem.

        Toolpath Optimization

        We customize cutting speeds, feeds, and tool movements in order to prevent heat buildup and eliminate shape deformity when machining.

        Tool Selection

        Tools with a sharp carbide or diamond coating are used in order to reduce the tool wear and achieve a smooth surface.

        Precision Machining

        Due to close attention being paid to dimensions and material behavior, the part is machined using 3- and 5-axis CNC milling or turning centers.

        Cooling & Chip Control

        Coolants and methods of the chip-breaker are used to control Ultem’s tendency to string and to reduce thermal stress.

        Post-Processing

        Parts get finished by polishing, deburring, and surface treatment (optional) as per final application needs.

        Quality Inspection

        Every part goes through the CMM inspection or dimensional verification to guarantee that all tolerances and specifications are met.

        Material Properties of Ultem

        Ultem is outstanding for its peculiar balance of properties.

        1. High Thermal Stability – for Continuous Use, to Temperatures up to 170°C (338°F)
        2. Flame Retardant – Conforms by itself to the UL94 V-0 standards
        3. Chemical Resistance – Tolerates acids, alcohols, and hydrocarbons.
        4. Dimensional Stability – Shrink little and little creep
        5. Electrical Insulation – Suitable for high-voltage components.
        6. Biocompatibility – (Medical and food grade uses)

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          TOPS Ultem Machining Capabilities

          Tops Precision is here to serve with all these processes for Ultem machining.

          Multi-Axis CNC Milling

          Multi-axis CNC milling enables us to do complex geometries and fine surfaces in one setup, shortens the cycle time, and controls the tolerances. It is ideal for aerospace, electronics, and parts that have been custom-designed in that they have several features that are angled and pocketed.

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            Multi-Axis CNC Milling​
            CNC Turning

            CNC Turning

            CNC turning provides accurate concentric features on cylindrical Ultem components in the form of bushings, couplings, and valves. The procedure guarantees a smooth finish, high-speed runs, and a very repeatable process for prototypes as well as mass production.

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              EDM Machining

              Fine features and perfect internal cuts are produced using EDM (Electrical Discharge Machining). There is no strain on the material in doing so. It is particularly useful for sharp corners, keyways, and enclosed compartments of Ultem parts, which are difficult to perform with traditional machining.

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                EDM Machining
                Grinding

                Grinding

                Grinding offers high precision surface finishing and dimensional control. It is widely applied to mating surfaces and wear-resistant parts to provide close fits and a nice finish on components requiring the best level of performance and reliability.

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                  Polishing

                  Ultem parts can also be polished with a high-gloss finish for a better aesthetic view or a clearer view. Polishing is commonly used in medical, display, and lighting industries, providing smooth and reflective surfaces, as well as reducing contamination risks reduction facilities.

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                    Polishing
                    Drilling and Tapping

                    Drilling and Tapping

                    Precision drilling and tapping are important in drilling and tapping clean, neatly done holes and threads on Ultem parts. Such operations will allow an easy integration with other parts and are commonly utilized on panels, mounts, and functional mechanics.

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                      Threading

                      Threading enables Ultem parts to be firmly fixed or connected with exterior hardware. Threads are machined to exact levels of depths and pitch regardless of internal or external nature, maintaining continuity between batches in production.

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                        Threading

                        Surface Finishes for Ultem

                        Here are some of its types

                        Surface Finishes for Ultem

                        As-Machining

                        This finish holds fine tool marks and high dimensional accuracy, typically to ±0.01 mm. It is suitable for functional or internal uses where good looks do not matter, and is perfect for the prototyping stages, which can determine fit and form without the additional finishing costs.

                        Polishing

                        Polished Ultem makes the material more visually appealing as well as increases light transmission, especially in transparent grades of the material such as Ultem 1000. It’s widely employed in medical and optical parts, where it’s important to have a smooth surface and clarity, as well as help remove micro-imperfections caused by machining.

                        Bead-Blasting

                        Bead-blasting evenly provides the surface with a flat texture, which reduces glare and conceals small flaws. It is commonly applied in industrial enclosures and cosmetic covers with enhanced tactile feel and paint or adhesive bonding, if such an application is required.

                        Chemical Cleaning

                        Chemical cleaning rejects machining residues, coolants, and contaminants and thus provides high surface purity. It is important for parts employed in the medical, aerospace, and cleanroom atmosphere, and also assists in preparing the surfaces for bonding or assembly.

                        Threading or Inserting

                        We can improve Ultem’s mechanical fastening abilities by the introduction of threads or metal inserts. Such an approach provides for lasting, robust connections, particularly for the areas that have to be assembled multiple times or connected to metal components in harsh applications.

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                          Different Grades of Ultem

                          TOPS machines various grades of Ultem based on your functional needs:

                          Grade

                          Key Features

                          Typical Uses

                          Ultem 1000

                          Unfilled PEI, best for strength and clarity

                          Electrical insulators, medical tools

                          Ultem 2300

                          30% glass-filled for higher rigidity and strength

                          Structural parts, aerospace brackets

                          Ultem 2100

                          10% glass-filled, improved stiffness

                          Precision housings, electronics

                          Ultem 1010

                          FDA-compliant, high-temp, biocompatible

                          Autoclavable medical parts, food tools

                          Ultem 2200

                          20% glass-filled, good balance of strength & machinability

                          Automotive, aerospace, electronics

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                            PEEK vs. Ultem Machining: What’s the Difference?

                            Property

                            Ultem (PEI)

                            PEEK

                            Heat Resistance

                            Up to 170°C

                            Up to 260°C

                            Cost

                            More cost-effective

                            Higher material cost

                            Machinability

                            Easier to machine

                            More demanding on tools

                            Strength

                            High, especially when glass-filled

                            Extremely high, good fatigue resistance

                            Biocompatibility

                            FDA & USP Class VI compliant

                            Suitable for implants

                            Ideal Applications

                            Housings, connectors, and medical tools

                            Bone screws, seals, high-load bearings

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                              Ultem Cost-Saving Design Tips for Parts

                              Here are some cost-saving tips we should use to make this process more effective:

                              • Avoid Sharp Corners – Apply radii to relieve stress and tool wear.
                              • Normalize Hole Size –for common drill bit diameter.
                              • Optimize Wall Thickness –Eliminate warping and increase structural integrity.
                              • Combine Parts – Integrate features to minimise assembly and tooling costs.
                              • Design for Fixing – have flat areas or grips for efficient clamping.

                              Applications of Machined Ultem Parts

                              The machined Ultem products are used throughout the industries for high-demand applications:

                              • Medical and surgical instruments
                              • Aerospace brackets and housings
                              • Semiconductor insulators
                              • Electrical and electronic components
                              • Food-grade parts and tooling
                              • Industrial valve elements and liquid connectors

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                                Want Custom Ultem CNC Machined Parts?

                                TOPS ships Ultem parts totally made to your specs – not compromised. From close-tolerance prototypes to complex production runs to finished assemblies, we provide our customers with constant quality, open communication, and fast turnaround.

                                We accept a build-to-print solution, reverse-engineered samples, or co-design concepts. Let us make your vision a functioning Ultem solution.

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                                Industries We Serve

                                TOPS has distributed machined parts made of Ultem to customers all over:

                                • Medical and Surgical –Diagnostic gadgets, autoclave-safe devices
                                • Aerospace –Insulators, brackets, and cabin pieces
                                • Auto – High heat housings, electrical connectors
                                • Electronics –PCB support, insulators, RF-blocking parts.
                                • Industrial Equipment – Fluid flow elements, manifolds

                                Food and Beverage – FDA-graded tools and trays.

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                                  Why Choose TOPS for Ultem Machining?

                                  Here are the main reasons why you should choose TOPS for Ultem services;

                                  State-of-the-Art Machining Facilities –For engineering plastics and tight tolerances

                                  Veteran Engineering – Master of expertise in thermoplastics and performance materials

                                  Full Production Lifecycle – From prototyping up to full-scale production and assembly

                                  Quality Assurance –ISO compliant testing and material traceability

                                  Global Delivery – Worldwide, quick delivery within the U.S., E.U., and Asia.

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                                    FAQs About ABS CNC Machining

                                    We can go with tolerances to ±0.01 mm depending upon geometry and part size.

                                    Yes, the majority of the grades, particularly Ultem 1010, are appropriate for autoclaving and steam sterilization.

                                    We can use FDA grades, as Ultem 1000 and Ultem 1010, in food contact and have been proven to be safe as a material.

                                    Ultem is strong in comparison to its weight benefits and is suited for the replacement of metals in non-load-bearing applications.

                                    Absolutely. Our core businesses include the construction of prototypes and shorter orders of Ultem and other engineering plastics.

                                    Yes, we can advise our engineers to provide you with optimal manufacturability and cost efficiency for your part.

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