High-temperature, chemically resistant Ultem (PEI) components for demanding microfluidic, medical, and industrial applications.
Ultem® is the trade name for Polyetherimide (PEI), a high-performance amorphous thermoplastic originally developed by GE Plastics and now produced by SABIC. It sits at the premium end of the engineering plastics range, offering a combination of thermal resistance, mechanical strength, chemical stability, and inherent flame retardancy that very few materials can match at a comparable price point to PEEK.
Ultem is semi-transparent amber in colour and is available in multiple grades, the most common being Ultem 1000 (unreinforced) and Ultem 2300 (30% glass-filled for greater stiffness and dimensional stability). FDA-compliant and USP Class VI grades are available for medical and life science applications. It is easily machined using conventional CNC processes, which makes it well suited to precision microfluidic components, manifolds, and housings where tight tolerances and complex geometries are required.
IPFL combines CNC micromilling, CNC turning, diamond-tool cutting, and laser machining to manufacture Ultem components to the tolerances your application demands. Ultem’s inherent stability during machining means it holds geometry well throughout the process, which is critical for microfluidic channel networks where dimensional accuracy directly affects flow behaviour.
For sealed fluidic assemblies, we use chemical bonding and thermal joining techniques appropriate to Ultem. Unlike COC, Ultem does not diffusion bond in the same way, so channel sealing is achieved using validated methods, depending on the chemical and pressure environment of your device. We will advise on the right approach for your application.
Every Ultem component we manufacture benefits from our ISO 9001-certified quality management system, full dimensional inspection, and a documented manufacturing record. Whether you need a small prototype batch or a production volume run, our process is consistent and repeatable.
Ultem is the material of choice when heat, chemistry, or fire safety rules out standard plastics. The sectors below represent our core customer base for Ultem components.
Medical Devices and Surgical Instruments
Ultem’s biocompatibility, steam sterilisation resistance, and USP Class VI compliance make it a strong choice for reusable surgical instruments, autoclavable trays, fluidic manifolds in diagnostic equipment, and instrument housings. It retains full mechanical strength through thousands of autoclave cycles, which matters for devices designed for repeated clinical use.
Life Sciences and Analytical Instruments
Laboratory and analytical equipment that uses aggressive reagents, operates at elevated temperatures, or requires consistent dimensional accuracy across a wide temperature range. Ultem performs where acrylic or polycarbonate would degrade or deform, and its resistance to hot water and steam makes it suitable for instruments that require in-line or autoclave sterilisation.
Aerospace and Defence
Ultem is well established in aerospace for components requiring FAR 25.853 flammability compliance, low smoke generation, and high strength-to-weight ratio. We machine Ultem parts for aerospace sub-assemblies, sensor housings, and fluid management components where both dimensional precision and fire safety certification are mandatory.
Electronics and Semiconductor
Electronic component housings, connectors, insulators, and semiconductor process equipment parts where high dielectric strength, stable electrical properties across a wide frequency range, and resistance to process chemicals are all required. Ultem’s combination of electrical and thermal performance is difficult to match in this application space.
Chemical Processing and Industrial Fluidics
Manifolds, valve bodies, and fluidic housings for chemical processing equipment handling aggressive reagents at elevated temperatures. Ultem resists a broad range of industrial chemicals and maintains dimensional stability under sustained thermal and chemical exposure, making it more durable in this environment than most standard engineering plastics.
Automotive and EV
Under-bonnet sensor housings, connectors, and fluid management components for automotive and electric vehicle applications where parts must survive sustained high temperatures, chemical exposure, and meet flammability standards. Ultem’s inherent UL94 V-0 rating without additives is a genuine advantage in EV battery management systems and high-voltage enclosures.
