Chemical Resistance in Injection Molded Ceramics

Molded ceramics boast exceptional properties, including outstanding chemical resistance, which makes them an excellent choice for applications in harsh environments where traditional materials such as metals might fail. Unlike metals, which can corrode and degrade when exposed to chemicals, ceramics maintain their integrity, even under extreme conditions. 

Reliable custom plastic and ceramic injection molders can produce high-quality components for a variety of applications. In today’s article, we’ll have a closer look at the chemical resistance of ceramics in injection molding and the applications that require this particular characteristic. 

Why are ceramics so much more resistant to corrosion than metals?

Ceramics are inherently resistant to harsh chemical environments because of their unique atomic structure, composed of tightly bonded atoms in a crystalline lattice. This structure is highly stable and doesn’t easily interact with chemicals. There are several factors that contribute to the chemical resistance:

• High melting points. With melting points often exceeding 1,832°F, ceramics can resist chemical reactions that can occur at lower temperatures in other materials. 
• Low reactivity. The ionic and covalent bonds in ceramics are stronger than the bonds in metals. This reduces the likelihood of reacting with chemicals, even under extreme conditions. 
• Crystalline structure. The crystalline nature further enhances the resistance to chemical attack. This structure is less prone to defects and degradation, ensuring that a molded part maintains its integrity over time. 
• Inertness: Many materials such as zirconia and alumina, are chemically inert. This means they do not easily interact with or dissolve in corrosive chemicals, which makes them perfect for environments where chemical stability is critical. 

Applications 

Because of the excellent chemical resistance of injection molded ceramics, they’re widely used across different industries. Some of the common applications include:

• Chemical processing. In facilities focused on chemical processing, components such as pumps, valves, and seals, are normally exposed to highly corrosive chemicals. Ceramics provide long-term durability and prevent contamination of the processed chemicals.
• Medical devices. Ceramics are usually used in medical devices that require high levels of chemical resistance, such as dental implants, surgical tools, and prosthetics. Their biocompatibility and resistance to bodily fluids make them ideal for long-term use in the human body. 
• Semiconductor manufacturing. The semiconductor industry requires materials that can withstand aggressive chemicals used in etching and cleaning processes. Injection molded ceramics are perfect for components like wafer carriers, nozzles, and other equipment exposed to the harsh environments. 
• Aerospace and defense. In aerospace and defense applications, these materials are used in components that must resist chemical attack while maintaining structural integrity under extreme conditions. These include thermal barrier coatings, insulators, and wear-resistant parts. 
• Automotive. The automotive industry benefits from the process in applications such as engine components, sensors, and exhaust systems. Ceramics ensure that these parts remain functional and durable in the presence of fuels, lubricants, and other aggressive chemicals.
• Oil and gas industry. The oil and gas industry operates in some of the most demanding environments, with equipment exposed to corrosive chemicals, extreme temperatures, and high pressures. Ceramic parts are used in components such as seals, bearings, and valves to secure reliable performance and longevity. 

Where can I find reliable custom plastic injection molders?

Whether you’re interested in learning more about the benefits of injection molded ceramics or wondering about the difference between injection molding and grinding, our dedicated team at Wunder Mold is here to answer all your questions and provide you with premium-quality service that meets your needs. We apply modern technology and have in place stringent quality control procedures to ensure our products meet the highest standards. Dial our number or send an email to sales@wundermold.com and let us know how we can make your project a success.