Overview
PEEK gears are high-performance polymer gearing components manufactured from polyether ether ketone (PEEK), a premium engineering thermoplastic renowned for its exceptional mechanical properties, chemical resistance, and thermal stability. These precision gears are designed to operate reliably under demanding conditions where traditional metal gears may be unsuitable due to weight, corrosion, lubrication requirements, or biocompatibility concerns. OrroMFG produces high-precision PEEK gears with tight tolerances and superior surface finishes, meeting the exacting requirements of semiconductor manufacturing, medical device, aerospace, and advanced industrial applications.
Our PEEK gears offer significant advantages over metal gears including reduced weight, inherent corrosion resistance, self-lubricating properties, and quiet operation. We manufacture both standard tooth forms and custom gear geometries using 5-axis CNC machining centers and precision gear hobbing equipment to achieve AGMA Q10-Q14 quality levels. Our PEEK gear portfolio includes spur gears, helical gears, bevel gears, worm gears, and pinion gears in sizes ranging from miniature medical device gears to large-diameter industrial gears. We offer various PEEK formulations including virgin PEEK, 30% carbon-filled PEEK, 30% glass-filled PEEK, and medical-grade PEEK (PEEK-OPTIMA and similar), each optimized for specific performance requirements.
Key Features
- Exceptional Mechanical Strength: High tensile strength, flexural modulus, and fatigue resistance comparable to many metal alloys at elevated temperatures.
- Wide Temperature Range: Continuous operating temperature up to 260°C (500°F), with short-term exposure up to 300°C; retains mechanical properties at cryogenic temperatures.
- Excellent Chemical Resistance: Resistant to a wide range of chemicals, acids, bases, solvents, and sterilization agents.
- Self-Lubricating: Inherently low friction coefficient eliminates the need for external lubrication in many applications.
- Biocompatible: Medical-grade PEEK meets ISO 10993 and USP Class VI requirements for medical and dental applications.
- Lightweight: Approximately 80% lighter than steel, reducing inertia and enabling higher operating speeds.
Material Specifications
| Property | Virgin PEEK | 30% Carbon-Filled PEEK | 30% Glass-Filled PEEK | Medical-Grade PEEK |
|---|---|---|---|---|
| Density (g/cm³) | 1.30 - 1.32 | 1.40 - 1.45 | 1.50 - 1.55 | 1.30 - 1.32 |
| Tensile Strength (MPa) | 90 - 100 | 130 - 150 | 120 - 140 | 90 - 100 |
| Tensile Modulus (GPa) | 3.6 - 4.0 | 7.5 - 9.0 | 7.0 - 8.5 | 3.6 - 4.0 |
| Flexural Strength (MPa) | 150 - 170 | 220 - 250 | 200 - 230 | 150 - 170 |
| Flexural Modulus (GPa) | 3.6 - 4.0 | 8.0 - 10.0 | 7.5 - 9.5 | 3.6 - 4.0 |
| HDT at 1.8 MPa (°C) | 150 - 160 | 240 - 260 | 230 - 250 | 150 - 160 |
| Continuous Service Temp (°C) | 260 | 260 | 260 | 260 |
| Hardness (Rockwell M) | 80 - 90 | 95 - 105 | 90 - 100 | 80 - 90 |
| Coefficient of Friction | 0.25 - 0.35 | 0.18 - 0.25 | 0.25 - 0.35 | 0.25 - 0.35 |
| Water Absorption (24h, %) | 0.1 - 0.2 | 0.05 - 0.15 | 0.1 - 0.2 | 0.1 - 0.2 |
Applications
Semiconductor Manufacturing
PEEK gears are essential components in semiconductor wafer processing equipment, including wafer handling robots, chemical mechanical polishing (CMP) tools, etchers, deposition systems, and inspection equipment. Their excellent chemical resistance to process chemistries, low particle generation, high purity, and ability to withstand vacuum and plasma environments make them ideal for semiconductor manufacturing. Carbon-filled PEEK gears are preferred for high-load wafer transport mechanisms where dimensional stability and wear resistance are critical.
Medical Devices and Dental Equipment
Medical-grade PEEK gears are widely used in surgical instruments, dental handpieces, implantable devices (when appropriately certified), drug delivery systems, diagnostic equipment, and patient monitoring devices. Their biocompatibility, sterilization resistance (autoclave, gamma, EtO), and lightweight nature make them the material of choice for medical gearing applications. PEEK gears in surgical robots and dental equipment provide precise, reliable power transmission with minimal noise and vibration.
Aerospace and Defense
In aerospace applications, PEEK gears are used in aircraft cabin systems, actuation mechanisms, sensor systems, and satellite components where weight reduction and high performance are critical. Their ability to withstand extreme temperature variations, radiation, and vacuum conditions makes them suitable for aerospace and space applications. Carbon-filled PEEK gears offer enhanced strength and stiffness for structural gearing requirements.
Automotive Industry
PEEK gears are increasingly used in automotive applications including transmission systems, fuel injection pumps, electric vehicle (EV) components, steering systems, and HVAC actuators. Their ability to operate at high temperatures under the hood, resist automotive fluids, and reduce noise and weight compared to metal gears drives their adoption in modern vehicle systems.
Food and Beverage Processing
Food-grade PEEK gears are used in food processing and packaging equipment where FDA compliance and resistance to cleaning chemicals and high-temperature washdowns are required. Applications include conveyor systems, filling machines, packaging lines, and slicing equipment.
Operating Conditions
- Temperature Range: -40°C to +260°C (-40°F to +500°F) continuous service; cryogenic grades available down to -196°C
- PV Limit: Up to 4,000 bar·m/s depending on material grade, lubrication, and operating conditions
- Torque Capacity: Up to 500 Nm depending on gear size, module, and material grade
- Speed Range: Up to 20,000 RPM for properly designed PEEK gears with optimized tooth geometry
- Chemical Compatibility: Resistant to most organic and inorganic chemicals, acids, bases, hydrocarbons, fuels, lubricants, and sterilization agents
- Sterilization Compatibility: Autoclave (134°C), gamma irradiation, ethylene oxide (EtO), dry heat, and cold sterilization
- Environmental Resistance: Excellent resistance to hydrolysis, UV radiation, and gamma radiation
Material Comparison
| Material | Strength | Temp Range | Chemical Resistance | Weight | Cost | Best For |
|---|---|---|---|---|---|---|
| PEEK (filled) | Very High | -40 to +260°C | Excellent | Low | Very High | High-performance, high-temp, medical/semiconductor |
| POM (Delrin) | Medium | -40 to +100°C | Good | Low | Low | General industrial, consumer products, low-load |
| Nylon (PA66) | Medium-High | -40 to +120°C | Fair | Low | Low-Medium | General industrial, moderate load, lubricated |
| Steel | Very High | -40 to +200°C+ | Poor | High | Medium | Heavy-duty, high-load, high-torque applications |
| Aluminum | Medium | -40 to +150°C | Fair | Medium | Medium | Light-duty, moderate load, weight-sensitive |
| Brass | Medium | -40 to +200°C | Fair | Medium | Medium-High | Low-friction, corrosion-resistant apps |
Choose PEEK gears when:
- High mechanical strength at elevated temperatures is required
- Chemical resistance and corrosion resistance are essential
- Biocompatibility or medical-grade certification is needed
- Lightweight design is critical for performance or energy efficiency
- Self-lubricating, maintenance-free operation is desired
- The application involves semiconductor manufacturing or medical devices
Customization Options
- Material Grades: Virgin PEEK, 10-40% carbon-filled, 10-40% glass-filled, PEEK with PTFE blend, medical-grade PEEK, ESD/conductive PEEK
- Gear Types: Spur gears, helical gears, bevel gears, miter gears, worm gears, rack and pinion, internal gears, planetary gears
- Size Range: Module 0.2 to Module 8; pitch diameter from 3mm to 500mm; bore sizes from 1mm to 100mm
- Quality Grades: AGMA Q8 to Q14; DIN 3962 Class 4 to 8; JIS N3 to N8
- Tooth Modifications: Profile crowning, tip relief, lead crowning, backlash optimization for specific applications
- Hub Configurations: Plain bore, keyway, set screw holes, press-fit, splined bore, custom hub profiles
- Tolerance Grades: Precision machined to IT4-IT7 dimensional tolerances
- Surface Finishes: As-machined, ground, polished, and deburred tooth flanks with Ra down to 0.4 μm
- Color Options: Natural amber, black (carbon-filled), brown (glass-filled), and custom colors on request
- Secondary Operations: Insert molding of metal hubs, pinning, fastening inserts, and assembly services
Quality Assurance
OrroMFG is committed to delivering PEEK gears of the highest precision and quality. Our manufacturing facilities operate under ISO 9001:2015 certification, with dedicated cleanroom production areas for semiconductor and medical-grade components. We employ state-of-the-art gear manufacturing equipment including CNC gear hobbers, gear shapers, gear grinders, and 5-axis machining centers to produce gears with exceptional dimensional accuracy and surface finish.
Quality control begins with incoming material verification using FTIR spectroscopy, DSC analysis, and mechanical property testing to confirm PEEK grade authenticity and conformance to specifications. In-process inspection includes tooth profile inspection on coordinate measuring machines (CMM), pitch accuracy measurement, runout verification, and surface roughness evaluation. Final inspection includes comprehensive gear measurement on specialized gear testing equipment to verify tooth profile, lead, pitch, backlash, and tooth thickness against AGMA, DIN, or customer-specific standards. For medical and semiconductor applications, we provide material certificates including FDA compliance declarations, USP Class VI test reports, ISO 10993 biocompatibility data, and full traceability documentation. Every PEEK gear we manufacture undergoes rigorous quality checks to ensure reliable performance and long service life in the most demanding applications.
