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Home / Mastering the 160℃ mold temperature controller: Which materials require 160℃?

Mastering the 160℃ mold temperature controller: Which materials require 160℃?

2025/11/12 By le zhan

PEEK, PSU, PEI injection molding materials(1)

Many injection molding plants fail to maintain a stable mold temperature of 160°C when producing high-temperature polymers, resulting in numerous scraps, rework, and mold damage. For example, a medical product manufacturer scrapped 1,200 PEEK components last year because its mold temperature was consistently maintained at 145°C—flow lines and warpage rendered these components unusable. Therefore, mastering 160°C mold temperature control is crucial for producing high-performance materials with specific properties. We will also inform you about the materials that require a 160°C mold temperature, their practical applications, and how Topstar’s 160°C mold temperature controller ensures accuracy.

160°C Mold Temperature Controller: Why 160°C is the “Optimal Temperature” for High-Temperature Materials

For materials with high melting points and poor flowability, a 160°C mold temperature solves three key challenges:

Good Flowability: High-temperature materials, such as PEEK or PSU, exhibit a viscous molten state. A 160°C mold temperature enables the material to maintain sufficient flowability, allowing it to fill thin walls, complex cavities, and tight tolerances, thereby avoiding short shots and flow marks.

Reduced internal stress: Rapid cooling of high-temperature polymers generates internal stress, leading to warping, cracking, or component embrittlement. At 160°C, the material cools more slowly, allowing it to crystallize or relax more evenly.

Mold release agent: Sticky, high-temperature materials can adhere to cold molds. At 160°C, friction is reduced, enabling the machine to demold parts cleanly and efficiently, which avoids damage and removes scrap from torn edges or deformed areas.

A plastics engineer at an automotive supplier explained, “For our PEEK sensors, 160°C is absolutely non-negotiable. Below this temperature, the scrap rate reaches 10%. At 160°C, the scrap rate drops to 0.8%—Topstar’s mold temperature controller locks the temperature within this range.”

Key materials that can be processed with a 160°C mold temperature controller

Not all plastics require a high temperature of 160°C; only high-performance polymers, designed for extreme environments (such as high temperatures, chemicals, and mechanical stress), do. The following four materials are common mold temperature controllers requiring 160°C:

PEEK: The most commonly used high-temperature polymer, used in medical implants, aerospace stents, and oil and gas components. Melting point is approximately 343°C; a mold temperature of 160°C ensures flowability and reduces stress.

PSU: An amorphous polymer used in food processing equipment, medical devices, and electrical insulators. The melting point is approximately 300°C; 160°C prevents component embrittlement and improves dimensional stability.

PEI, also known as “Ultem”: Used in aerospace interiors, automotive engine compartment components, and 3D printing consumables. The melting point is approximately 337°C; 160°C enhances its flowability in thin-walled parts.

PA 46: A semi-crystalline nylon used in high-temperature gears, bearings, and connectors. The melting point is approximately 295°C; the operator uses a 160°C mold temperature controller to control crystallization for maximum strength and wear resistance.

Key materials that can be processed with a 160°C mold temperature controller

Optimizing PEEK Material Processing

PEEK is the gold standard for high-temperature injection molding, and the manufacture of high-quality parts relies entirely on a 160°C mold temperature controller. Topstar’s 160°C mold temperature controller maintains an accuracy of ±0.5°C, which is crucial for PEEK material, as a 5°C temperature difference can cause flow lines. It also ensures uniform heat distribution, which is essential for PEEK parts that often have complex geometries. Topstar’s 160°C mold temperature controller utilizes a high-flow pump to evenly circulate heat transfer oil, ensuring that each cavity reaches 160°C without cold spots. It also supports a digital PID control system, enabling real-time temperature adjustments to prevent overheating and maintain optimal temperature. Mechanical Properties of PEEK. Ensuring proper mold temperature control prevents PEEK material degradation, yellowing, and embrittlement.

PSU/PEI – Processing Amorphous High-Temperature Polymers

PSU and PEI are amorphous polymers with properties different from PEEK, but they still require a 160°C mold temperature controller for optimal performance. Manufacturers commonly use PSU in FDA-approved food contact parts and medical device housings. A 160°C mold temperature controller prevents stress whitening, ensuring parts can withstand repeated steam sterilization. Manufacturers favor PEI for its flame retardancy and strength at 170°C. A 160°C mold allows PEI to flow into thin-walled molds for manufacturing electrical connectors and aerospace panels.

Topstar’s 160°C mold temperature controller, employing dual-zone heating technology, excels in this area and is ideal for molds with multiple cavities or complex cores. One electronics manufacturer utilizes it for PEI connectors, noting that “Dual-zone heating allows us to reach 160°C on both the core and cavity simultaneously.” Our connectors now fit perfectly, eliminating the need for rework. “

Ultem injection molding

Designed explicitly for High-Temperature Materials

Topstar’s 160°C mold temperature controller is not a “standard” product, but instead explicitly designed for materials such as PEEK, PSU, PEI, and PA 46. Key features include:

Digital PID Control: Automatically adjusts heating power to maintain a temperature of 160°C, even during injection molding machine operation, despite temperature fluctuations. No manual adjustment is required; the system automatically operates once it is set.

High-Temperature Heat Transfer Oil Compatibility: Uses heat transfer oil rated at 300°C, ensuring stable heat transfer at 160°C without performance degradation.

Self-Diagnostic Alarms: Alerts operators to temperature deviations, pump malfunctions, or low oil levels—preventing scrap.

Small Footprint: Ideal for small factory spaces, this model features a user-friendly touchscreen that displays real-time mold temperature, cycle count, and maintenance alarms.

One OEM injection molding company tested three brands before choosing Topstar: “Topstar’s controller is the only one that can maintain a stable 160°C PEEK injection temperature 24/7.” Other brands exhibit temperature fluctuations of 8-10℃.

160°C mold temperature controller 5-5

160℃ High-Temperature Processing for High-Quality, High-Value Parts

160℃ mold temperature controllers are ideal for high-temperature polymer processing. For materials such as PEEK, PSU, PEI, and PA 46, Topstar’s 160℃ mold temperature controllers are specifically designed to meet the unique needs of these materials. Their accuracy, reliability, and ease of use easily handle even the most complex production processes. If you are processing high-temperature materials, do not choose controllers prone to drift or failure; Topstar’s mold temperature controllers provide consistently stable results.

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