Medical PEEK Injection Using a Shut-Off Hot Runner System: A Technical Innovation Driving Economic Performance

Written by Top Clean Packaging - Published on 29 May 2026

Medical PEEK (PolyEtherEtherKetone) is now recognized as one of the highest-performing polymers for demanding applications. Combining exceptional mechanical strength, chemical stability, and biocompatibility, it has become essential in industries such as medical and aerospace, where reliability and precision allow no compromise. However, this technological excellence comes at a price: a particularly high material cost, requiring rigorous control of production waste.

With this challenge in mind, the R&D and Tooling teams of Top Clean Packaging Group have been developing an innovative solution over the past two years: a shut-off hot runner system specifically designed for medical PEEK injection molding. The objective is clear: eliminate the injection sprue - the main source of material waste - in order to optimize production yields while significantly improving industrial profitability.

In a context where every gram of material matters, this innovation represents a major economic advantage, offering manufacturers a rapid return on investment. Initial trials conducted on a prototype mold have already validated the industrial feasibility of the technology while confirming its strong technical and economic potential.

Key Success Factors of the Project

High-Precision Thermal Regulation

Processing PEEK requires perfect temperature control. To meet this challenge, a hydraulic mold temperature control system capable of reaching 200°C was developed. This technological choice, preferred over an electric solution, ensures optimal thermal homogeneity throughout the cavities, particularly around the shut-off system.

Controlled Thermal Continuity

Significant engineering work was also carried out on the hot runner system to ensure perfect thermal continuity from the nozzle to the injection point. This stability is essential to preserve the material’s properties and guarantee process repeatability.

Optimized Injection Point

The diameter and depth of the injection point were precisely adjusted to meet the specific requirements of medical PEEK while ensuring flawless surface finishing. The geometries and wall thicknesses of the part in this area were also redesigned to improve filling performance and final mechanical strength.

A Solution Now Industrialized

Today, Top Clean Packaging Group has reached a new milestone by industrializing a medical PEEK product incorporating direct injection through a shut-off hot runner system.

Results:

elimination of the injection sprue,
significant reduction in material waste,
improved overall project profitability,
maintenance of high-quality standards.

This innovation perfectly illustrates the Group’s ability to combine technical expertise, industrial performance, and economic optimization for very high value-added materials.

Do you have a project in mind? Contact our team.