Detailed Introduction

This miniature sensor plastic component series adopts PEEK and PEI ultra-high-performance engineering plastics, which satisfy extreme dimensional stability requirements for micro thin-wall structures inside engine compartments with long-term high heat. Compared with LCP/PBT, PEEK and PEI feature far higher heat resistance, hydrolysis resistance and mechanical strength, effectively preventing dimensional drift of small insulating sleeves and positioning bases under sustained ultra-high temperature, vibration and oil vapor, thus eliminating poor sensor signal contact.

• PEEK: Highest mechanical strength, wear resistance and thermal stability, suitable for load-bearing contact sleeves and structural shells with frequent friction.
• PEI (Ultem): Balanced high-temperature insulation, easy molding for ultra-thin micro parts, ideal for miniature isolation sleeves and multi-pin mounting bases.

The product portfolio covers three core matching assemblies: cylindrical metal composite sensor connector housings with locking grooves, batch tiny conical insulating sleeves for terminal isolation, and twin-cavity rectangular mounting base mold prototypes with dense micro pin slots. The miniature insulating sleeves provide terminal isolation and anti-short-circuit protection; metal-plastic integrated cylindrical shells offer mechanical protection and waterproof positioning for sensor probes; twin-cavity mounting bases are for fixed installation of multi-channel sensor signal terminals. Optimized ultra-high-temperature thin-wall mold flow design solves filling shortage and warpage defects of micro tiny PEEK/PEI plastic parts during precision injection molding.

Complete Production Workflow

1. Micro precision mold core processing: 5-axis micro CNC fine milling, ultra-micro sinker EDM for tiny thin-wall contours and micro pin slots
2. Vacuum stress relief heat treatment for micro mold steel to stabilize tiny cavity dimensions under continuous high-temperature micro injection cycles
3. Multi-stage ultra-fine mirror polishing to eliminate tiny burrs and reduce PEEK/PEI high-viscosity melt adhesion
4. Segmented high-temperature precision micro injection molding tailored for high-performance polymers
5. Post-molding full 3D micro coordinate inspection, micro burr trimming and long-term high-temperature thermal aging stability testing

All finished micro plastic parts pass high-temperature dimensional stability, insulation resistance and oil hydrolysis verification. Custom development is supported based on customer sensor terminal drawings: sleeve inner diameter, base pin layout, wall thickness and polymer grade can be adjusted according to sensor ultra-high operating temperature and signal precision requirements. This series widely matches automotive engine temperature sensors, pressure sensors and new energy vehicle battery monitoring miniature signal sensors.

Specification Table