5-Axis CNC Machined PEEK Custom Insulation Parts for Industrial Sensor Module
Project Overview
We delivered custom PEEK precision insulation components for a European industrial sensor manufacturer. The component includes complex angled cavities and thin-wall geometry. The client required excellent electrical isolation, high heat resistance and chemical inertness. Using 5-axis CNC machining, we finished all features in a single setup, supplied prototypes and low-volume batches within 10 working days.
Client Background
The client is a European Tier 2 supplier of industrial sensors. Their former machining vendor struggled with consistent thin-wall control on PEEK parts. Thermal warpage and failed insulation tests repeatedly delayed their product validation. They searched for a manufacturer with proven experience machining high-performance engineering plastics.
Key Challenges
- PEEK easily generates heat during cutting, which causes thin-wall distortion.
- Angled holes and multi-plane features would introduce stacked tolerance errors if processed on 3-axis machines with repeated re-clamping.
- Metal debris trapped on part surfaces compromises electrical insulation performance.
- Every piece in the batch must undergo full dimensional check and insulation testing.
Our Manufacturing Solution
- Deploy 5-axis CNC machining to complete all angled features in one clamping operation to eliminate position offset.
- Optimize cutting parameters and custom fixtures to reduce cutting heat and minimize PEEK thermal deformation.
- Carry out specialized ultrasonic cleaning to remove all micro metal particles to guarantee insulation performance.
- Conduct CMM dimensional inspection and insulation resistance testing for all parts before delivery.
Project Specifications
| Item | Parameter |
|---|---|
| Material | PEEK (Polyetheretherketone) |
| Machining Method | 5-axis CNC machining |
| Insulation Resistance | >10¹² Ω |
| Lead Time | 10 working days |
| Surface Finish | Deburred & Ultrasonically Cleaned |
Measurable Project Outcomes
Zero thermal warpage on all finished parts
100% pass rate of insulation resistance testing
All dimensions maintained within ±0.02 mm tolerance
Completed and shipped within 10 working days
Zero rework required for the full batch
Application
Industrial sensor modules, electrical insulation assemblies, high-temperature testing equipment, chemical monitoring instruments
