Orion continues to expand its portfolio of ultra-high-performance thermoplastics with the successful development and commercialization of PBI (polybenzimidazole)–based compounds, engineered for use in the most extreme thermal and mechanical environments. By compounding PBI with advanced reinforcements and polymer systems — including glass fiber, carbon fiber, and high-performance blends with PEEK and other engineered resins — Orion is delivering materials that redefine what’s possible in heat-resistant polymer technology.
PBI is widely recognized as one of the highest-performing engineering polymers available, offering exceptional thermal stability, chemical resistance, and mechanical integrity at continuous-use temperatures exceeding 400°C. However, its inherent processing challenges and cost have traditionally limited its use. Orion’s formulation and processing expertise now make reinforced and blended PBI compounds a practical solution for specialized applications where conventional high-temperature polymers reach their limits.
“PBI has long been the benchmark for extreme heat performance,” said Ryan Divens. “Our ability to compound it with other reinforcements and high-end polymers like PEEK opens new doors for engineers who need materials that perform where metal or ceramics once dominated.”
Next-Level Performance Through Reinforcement and Blending
Orion’s proprietary compounding approaches combine PBI’s inherent stability with the complementary strengths of:
These compounds are designed for injection molding, extrusion, and compression molding, enabling customers to produce precision components for demanding environments.
Applications in Extreme Conditions
Orion’s PBI-based materials are already under evaluation or in production in applications such as:
“Our work with PBI represents the intersection of materials science and manufacturing innovation,” said Ryan. “It’s about enabling customers to solve problems that were once thought unsolvable — and expanding the performance envelope of thermoplastics.”
As Orion continues to refine processing methods for ultra-high-temperature polymers, its growing capabilities in PBI compounding and hybrid formulations further strengthen the company’s position as a leader in advanced material development for the world’s most demanding applications.