Ultem CNC Machining Services

Custom PEI machined parts for aerospace, medical, electronics and industrial use.

✔ Ultem 1000 / 2300 / 1010 / 2100
✔ Tight Tolerances to ±0.01 mm
✔ Prototype to Mass Production
✔ ISO Quality Control
✔ Fast Quote in 24 Hours

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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.

    Ultem CNC Machining

    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.

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          Why Choose CNC Machining for Ultem?

          Why machine Ultem instead of molding?

          • No mold cost
          • Fast prototypes
          • Tight tolerances
          • Complex low-volume parts
          • Better for engineering validation

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            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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                                Ultem vs PEEK vs Delrin vs Nylon

                                Material
                                Heat Resistance
                                Cost
                                Strength
                                Best Use
                                UltemHighMediumHighElectronics
                                PEEKVery HighHighVery HighAerospace
                                DelrinMediumLowHighMechanical
                                NylonMediumLowToughWear parts

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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.

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                                    Applications of Machined Ultem Parts

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

                                    Aerospace

                                    Lightweight brackets, insulators, cabin components

                                    Medical

                                    Autoclave-safe trays, instruments, housings

                                    Electronics

                                    High voltage insulators, PCB supports, connectors

                                    Semiconductor

                                    Cleanroom fixtures, static-safe parts

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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.

                                      Want Custom Ultem CNC Machined Parts

                                      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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                                        Need Custom Ultem Parts?

                                        Send your drawing today for:

                                        ✔ DFM feedback
                                        ✔ Material recommendation
                                        ✔ Fast quotation
                                        ✔ Prototype lead time options

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                                          FAQs About Ultem CNC Machining

                                          Ultem is used for aerospace, medical, electronics, semiconductor and industrial components requiring heat resistance and strength.

                                          Yes. Ultem machines well when proper tooling and heat control are used.

                                          TOPS can machine Ultem to ±0.01 mm depending on geometry.

                                          Ultem is more economical, while PEEK offers higher temperature and wear performance.

                                          Yes. Many Ultem grades tolerate repeated autoclave cycles.

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