When to Choose High-End Materials Such as Ultem 1000 for Your Part

At Gemini Plastics, Inc., with 50+ years of plastics manufacturing experience and capabilities that span CNC machining, injection molding, vacuum forming, and hot stamping, we know there’s tremendous value in selecting the right material for your part. One standout in high-performance polymers is Ultem 1000, a premium grade of polyetherimide (PEI) that is worth considering when top-tier performance is essential.

What Makes Ultem 1000 So Exceptional?

Ultem 1000, developed by SABIC (formerly GE), is an unfilled, amorphous PEI resin with remarkable characteristics:

• High heat resistance: Glass transition temperature around 217 °C (430 °F), with continuous use up to ~170 °C (340 °F).

• Flame retardancy: Meets UL 94 V‑0, V‑2, and 5VA standards; complies with aerospace FAR 25.853.

• Dimensional integrity: Excellent stability with low creep and shrinkage, ideal for tight-tolerance parts.

• Chemical resilience: Robust resistance to many solvents, oils, and fluids; limited attack from ketones and chlorinated solvents.

• Electrical superiority: Strong dielectric strength and insulation properties, dielectric strength up to ~830 V/mil (in oil).

• Regulatory readiness: RoHS-compliant; natural grades are halogen-free; available in FDA, USP Class VI, and biocompatible variants.

When Should You Opt for Ultem 1000?

Here are the scenarios where Ultem 1000 truly shines:

1. High-Temperature Environments

If your part faces sustained heat (think aircraft interiors, under‑hood automotive components, or industrial thermal systems) Ultem 1000’s ability to maintain strength and shape makes it a top choice. Its high Tg and low creep offer unmatched reliability.

2. Critical Flame Retardancy

In regulatory-heavy sectors like aerospace or electrical enclosures where UL94 or FAR 25.853 ratings are mandatory, Ultem 1000 delivers natural flame retardancy without added chemicals.

3. Stringent Dimensional and Mechanical Requirements

For parts requiring tight dimensional tolerances—such as precision lens holders or electronic connectors—Ultem 1000 offers stability across temperature and humidity fluctuations.

4. Electrical Insulation Needs

Its high dielectric constant and surface resistivity make Ultem 1000 ideal for insulators, circuit supports, coil forms, and connector parts in electronics and energy systems.

5. Chemical- or Sterilization-Exposed Applications

Medical devices, laboratory components, or parts exposed to fuels and solvents benefit from Ultem 1000’s chemical resistance and sterilization compatibility (e.g., steam, gamma, EtO).

6. Regulatory-Sensitive or Clean Environments

In industries subject to food contact or medical regulations, Ultem 1000 delivers with compliance-ready grades and options for USP Class VI, FDA, or biocompatible formulation.

7. Machinability & Fabrication Flexibility

Whether you need CNC-machined parts, molded shapes, films, or extruded profiles, Ultem 1000 works across a wide gamut of fabrication methods—from additive manufacturing to injection molding and extrusion.

Index Your Decision with This Quick-Check Table

Criterion	Ultem 1000 Advantage
Operating Temp >150 °C	Outstanding thermal performance
Flame Resistance Required	Meets UL 94 & aerospace standards naturally
Critical Tolerance / Stability	Low creep, deformation, and expansion
Electrical Insulation Needed	High dielectric strength & resistant to moisture
Exposure to Chemicals/Sterilization	Highly resistant and sterilizable
Regulatory Compliance	Options for FDA, USP Class VI, RoHS, etc.
Fabrication Method	Compatible with molding, machining, extrusion, and AM methods

How Gemini Plastics Can Help

When Ultem 1000 is the right match for your part, Gemini Plastics is your trusted partner:

• Our CNC machining delivers tight tolerances and smooth finishes for high-performance parts.

• Injection molding, vacuum forming, and hot stamping adapt precision and volume—perfect for prototyping or full-scale runs.

• We stand out with fast quoting, real human support, and seamless CAD file intake, without guesswork.

Let us help assess whether Ultem 1000 fits your project’s unique demands. We'll ensure you get the right balance of materials science and fabrication expertise—even for the most demanding applications.