HiSiaddi is an innovative foreign trade service provider driven by dual engines of technology transformation and foreign trade services. It has established a service system of "1+2+3+4=1" and can supply original-source PEI products from multiple well-known brands. As a foreign trader with independent R&D capabilities, HiSiaddi has repeatedly collaborated with manufacturers on technology conversion and accurately captured market demands, successfully resolving various customized PEI product requirements for clients. Below is a case of HiSiaddi addressing customized PEI demands.
Please contact HiSiaddi customer service if you require further customized services.
HiSiaddi coordinated process transformation at partner factories to deliver exclusive customized materials, securing an annual procurement order of 65 tons
The purchaser is Tokyo Auto-Elec Co., Ltd., a core manufacturer of mid-to-high-end precision automotive electronics in Japan. Its main products include insulated frames for new energy vehicle electric controls, millimeter-wave radar bases for vehicles, and high-temperature resistant connector components for power batteries, which supply Toyota and Nissan’s new energy vehicle industrial chains. The enterprise has long imported SABIC ULTEM-series PEI resin from the US. Faced with tight production capacity of overseas original manufacturers, skyrocketing international freight costs, and extended order lead times exceeding 90 days, the company launched a localization substitution project for domestically produced PEI with an annual customized demand of 65 tons, all consisting of glass fiber reinforced high-temperature resistant special PEI, with no spot general injection-grade raw materials purchased.
The client issued Japanese-English bilingual technical specifications for customization, with indicators far stricter than national standards for general PEI:
1. Heat resistance: Heat deflection temperature ≥215℃, no creep deformation under continuous long-term use at 150℃;
2. Modification ratio: 20% chopped alkali-free glass fiber uniform reinforcement, zero dust from glass fiber precipitation, tensile strength ≥165MPa, stable dielectric constant at 3.1±0.05;
3. Impurity control: Low small-molecule volatilization, residual monomers <150ppm, halogen-free and phosphorus-free flame retardant, complying with automotive halogen-free environmental standards;
4. Processability: Stable melt flow index at 7.8±0.4g/10min, compatible with high-speed precision injection molding, no silver streaks or bubbles on thin-walled parts.
The client previously independently contacted three domestic PEI manufacturers. The main production lines of these factories were dedicated to mass-producing general household appliance and ordinary industrial-grade PEI, and conventional products commonly suffered from glass fiber agglomeration, excessive small-molecule volatilization, wide melt flow index fluctuation, and severe high-temperature creep. Their standardized polymerization and twin-screw modification production lines required full line emptying, replacement of special additives and screw components for process transformation. Restricted by production costs and production scheduling, manufacturers were unwilling to develop exclusive formulas and production processes for the client separately. Five rounds of sample delivery and testing at Japanese laboratories all failed, stalling the customization project. Upon recommendation by the Japan Fine Chemicals Association, the client fully entrusted HiSiaddi to coordinate the entire process including formula customization, lab and pilot testing, mass production implementation, and compliance support.
1. Replacement of halogen-free low-volatility additive system: General PEI adopts halogen-containing stabilizers and low-cost lubricant additives, which volatilize and precipitate easily during high-temperature molding and violate automotive halogen-free regulations. All additives must be replaced with high-end eco-friendly hindered phenol antioxidants and polysiloxane lubricants, followed by readjustment of additive proportions. Most manufacturers lack R&D experience for matching additive formulas.
2. Optimization of uniform glass fiber dispersion process: Conventional feeding methods easily cause glass fiber agglomeration, leading to uneven local strength and fluctuating dielectric properties of precision electronic components. It is necessary to adjust twin-screw screw layout, segmented temperature control, and stepwise feeding processes to reduce screw shear force and achieve uniform glass fiber dispersion inside the resin.
3. Precise control of narrow melt flow index range: Affected by residual polymerization materials and extrusion backpressure fluctuations, melt flow index fluctuation of general mass production processes exceeds ±1.2g/10min, failing to meet the strict tolerance of ±0.4 required by the client. Fine-tuning of polymerization end-capping processes and extrusion temperature curves is required, along with separate exclusive production control standards.
Equipped with polymer material engineers, HiSiaddi screened two specialized domestic manufacturers with independent PEI polymerization and flexible modification pilot lines, and implemented the project in three phases: small sample trial production → pilot scale verification → mass production finalization.
First, full upgrade of the additive system: eliminate halogen-containing and easily precipitated additives, select halogen-free additives complying with Japanese JIS automotive environmental standards, and conduct more than 20 groups of ratio debugging to strictly control small-molecule volatilization and precipitation. Second, optimize twin-screw equipment structure and processes: feed glass fiber in two batches after low-temperature melting of resin to reduce fiber breakage and agglomeration caused by high-speed shearing. Third, fine-tune post-polymerization end-capping reaction conditions and extruder segmented backpressure to stabilize melt flow rate. Ultimately, all indicators of small samples including melt flow index, heat resistance, and dielectric properties passed inspection. 5kg samples were sent to Japan and successfully passed full aging, dielectric and environmental tests for automotive components.
After confirmation of qualified small samples, HiSiaddi coordinated the factory to shut down and clean the entire production line for dust and impurity removal, activating an isolated dedicated production line. High-purity bulk PEI substrate and electronic-grade alkali-free glass fiber were adopted for all raw materials, fully replicating all process parameters from small trials. The client used pilot materials for continuous 72-hour high-speed injection molding of radar bases and electric control insulation parts; finished products had no silver streaks or bubbles, with stable dimensional and mechanical properties, smoothly passing incoming inspection for Toyota’s supply chain access.
After pilot acceptance, an annual 65-ton order divided into 5 batches was finalized. Custom packaging: Inner vacuum aluminum foil moisture-proof packaging + 25kg anti-static rust-proof iron drums, meeting storage and feeding requirements of Japanese dust-free workshops. Compliance: HiSiaddi coordinated third-party testing institutions to issue full sets of test reports for JIS halogen-free, RoHS and REACH-SVHC, compiled Japanese-English bilingual CLP labels and Version 9 compliant SDS, attached original factory COA quality inspection certificates for each batch, and established a full-batch product traceability ledger to avoid cross-contamination from mixed grades.
The first batch of 14 tons of customized modified PEI completed dangerous goods customs declaration and sea freight to Japan. After raw material commissioning, the yield rate of components rose from less than 70% in previous sample trials to 99.5%. Compared with imported SABIC raw materials, the comprehensive domestic procurement cost decreased by 30%, and delivery lead time was shortened from over 90 days to less than 30 days.
In the following year, the client launched a new 800V high-voltage new energy connector project and again entrusted HiSiaddi to collaborate with factories to develop low-water-absorption modified PEI grades, adding an annual customized order of 37 tons. Partner factories improved high-end PEI customized production lines relying on this Japanese automotive order, and their products have since entered Hyundai and Kia’s automotive supply chains in South Korea.
Most domestic PEI manufacturers focus on mass production of general bulk materials with fixed production lines and formulas, lacking willingness to transform production lines for high-end automotive special material customization. Mid-to-high-end Japanese automotive electronics clients are constrained by multiple regulations including JIS, halogen-free standards and whole-vehicle supply chain requirements, with stringent thresholds for raw material heat resistance, dielectric properties and environmental compliance that cannot be met by off-the-shelf general PEI. Supported by professional polymer technology, HiSiaddi breaks technical barriers between overseas customized demands and domestic factory process improvements, delivering end-to-end solutions from formula R&D, process debugging and sample verification to compliant shipment. It facilitates domestic high-end modified PEI to achieve import substitution and enter the high-end new energy vehicle supply chain in Japan.
Please contact HiSiaddi customer service if you require further customized services.
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