- Processes
- Polymer Processing
- Blow Molding
- Injection Molding
- Metal Injection Molding
- Thermoforming
- Metal Casting
- Centrifugal Casting
- Die Casting
- Investment Casting
- Permanent Mold
- Sand Casting
- Shell Mold Casting
- Machining
- Milling
- Turning
- Hole-making
- Drill Size Chart
- Tap Size Chart
- Sheet Metal Fabrication
- Forming
- Cutting with shear
- Cutting without shear
- Gauge Size Chart
- Additive Fabrication
- SLA
- FDM
- SLS
- DMLS
- 3D Printing
- Inkjet Printing
- Jetted Photopolymer
- LOM
- Materials
- Metals
- Plastics
- Case Studies
- Cost Analysis
- Part Redesign
- Product Development
- Resources
- Curriculum Resources
- Glossary
Plastic is a commercial name for a group of materials
that while being processed, can be pushed or formed into
almost any desired shape and then retain that shape.
Plastics can be cast, molded, or pressed into an unlimited variety of
shapes. They are one of the most used materials on a
volume basis in industrial and commercial life.
Plastics are on par with metals, wood, and ceramics and
are essential to the needs of virtually the entire
spectrum of business. Plastics, properly applied, will perform functions at a
cost that other materials cannot match.
Most plastics can be classified as either thermoplastic
or thermosetting materials. Thermoplastic materials can
be formed into desired shapes under heat and pressure
and become solids on cooling. If they are subjected to
the same conditions of heat and pressure, they can be
reprocessed into new shapes. Thermosetting materials
are like concrete, once processed and shaped, they
cannot be reshaped. Today, the vast majority of
plastics are thermoplastics.
Plastics are made up of polymers. Polymeric
materials are characterized by long chains of repeated
molecule units known as "mers". These long chains
intertwine to form the bulk of the plastic. The ways in
which the chains intertwine determine the plastic's
macroscopic properties. Typically, the polymer chain
orientations are random and give the plastic an amorphous
structure. Amorphous plastics have good
impact strength and toughness. Examples include
acrylonitrile-butadiene-styrene (ABS), styrene-acrylonitrile
copolymer (SAN), polyvinyl chloride (PVC), polycarbonate
(PC), and polystyrene (PS).
If instead the polymer chains take an orderly,
densely packed arrangement, the plastic is said to be
crystalline. Crystalline plastics share many properties
with crystals, and typically will have lower elongation
and flexibility than amorphous plastics, and better
chemical resistance. Examples of crystalline plastics
include acetal, polyamide (PA; nylon), polyethylene
(PE), polypropylene (PP), polyester (PET, PBT), and
polyphenylene sulfide (PPS). Advances
in chemistry have made the distinction between
crystalline and amorphous less clear, since some
materials like nylon are formulated both as a
crystalline material and as an amorphous material.
Thermoplastics and Thermosets
Material name | Abbreviation | Trade names | Description | Applications |
Acetal | POM | Celcon, Delrin, Hostaform, Lucel | Strong, rigid, excellent fatigue resistance, excellent creep resistance, chemical resistance, moisture resistance, naturally opaque white, low/medium cost | Bearings, cams, gears, handles, plumbing components, rollers, rotors, slide guides, valves |
Acrylic | PMMA | Diakon, Oroglas, Lucite, Plexiglas | Rigid, brittle, scratch resistant, transparent, optical clarity, low/medium cost | Display stands, knobs, lenses, light housings, panels, reflectors, signs, shelves, trays |
Acrylonitrile Butadiene Styrene | ABS | Cycolac, Magnum, Novodur, Terluran | Strong, flexible, low mold shrinkage (tight tolerances), chemical resistance, electroplating capability, naturally opaque, low/medium cost | Automotive (consoles, panels, trim, vents), boxes, gauges, housings, inhalors, toys |
Cellulose Acetate | CA | Dexel, Cellidor, Setilithe | Tough, transparent, high cost | Handles, eyeglass frames |
Polyamide 6 (Nylon) | PA6 | Akulon, Ultramid, Grilon | High strength, fatigue resistance, chemical resistance, low creep, low friction, almost opaque/white, medium/high cost | Bearings, bushings, gears, rollers, wheels |
Polyamide 6/6 (Nylon) | PA6/6 | Kopa, Zytel, Radilon | High strength, fatigue resistance, chemical resistance, low creep, low friction, almost opaque/white, medium/high cost | Handles, levers, small housings, zip ties |
Polyamide 11+12 (Nylon) | PA11+12 | Rilsan, Grilamid | High strength, fatigue resistance, chemical resistance, low creep, low friction, almost opaque to clear, very high cost | Air filters, eyeglass frames, safety masks |
Polycarbonate | PC | Calibre, Lexan, Makrolon | Very tough, temperature resistance, dimensional stability, transparent, high cost | Automotive (panels, lenses, consoles), bottles, containers, housings, light covers, reflectors, safety helmets and shields |
Polyester - Thermoplastic | PBT, PET | Celanex, Crastin, Lupox, Rynite, Valox | Rigid, heat resistance, chemical resistance, medium/high cost | Automotive (filters, handles, pumps), bearings, cams, electrical components (connectors, sensors), gears, housings, rollers, switches, valves |
Polyether Sulphone | PES | Victrex, Udel | Tough, very high chemical resistance, clear, very high cost | Valves |
Polyetheretherketone | PEEKEEK | Strong, thermal stability, chemical resistance, abrasion resistance, low moisture absorption | Aircraft components, electrical connectors, pump impellers, seals | |
Polyetherimide | PEI | Ultem | Heat resistance, flame resistance, transparent (amber color) | Electrical components (connectors, boards, switches), covers, sheilds, surgical tools |
Polyethylene - Low Density | LDPE | Alkathene, Escorene, Novex | Lightweight, tough and flexible, excellent chemical resistance, natural waxy appearance, low cost | Kitchenware, housings, covers, and containers |
Polyethylene - High Density | HDPE | Eraclene, Hostalen, Stamylan | Tough and stiff, excellent chemical resistance, natural waxy appearance, low cost | Chair seats, housings, covers, and containers |
Polyphenylene Oxide | PPO | Noryl, Thermocomp, Vamporan | Tough, heat resistance, flame resistance, dimensional stability, low water absorption, electroplating capability, high cost | Automotive (housings, panels), electrical components, housings, plumbing components |
Polyphenylene Sulphide | PPS | Ryton, Fortron | Very high strength, heat resistance, brown, very high cost | Bearings, covers, fuel system components, guides, switches, and shields |
Polypropylene | PP | Novolen, Appryl, Escorene | Lightweight, heat resistance, high chemical resistance, scratch resistance, natural waxy appearance, tough and stiff, low cost. | Automotive (bumpers, covers, trim), bottles, caps, crates, handles, housings |
Polystyrene - General purpose | GPPS | Lacqrene, Styron, Solarene | Brittle, transparent, low cost | Cosmetics packaging, pens |
Polystyrene - High impact | HIPS | Polystyrol, Kostil, Polystar | Impact strength, rigidity, toughness, dimensional stability, naturally translucent, low cost | Electronic housings, food containers, toys |
Polyvinyl Chloride - Plasticised | PVC | Welvic, Varlan | Tough, flexible, flame resistance, transparent or opaque, low cost | Electrical insulation, housewares, medical tubing, shoe soles, toys |
Polyvinyl Chloride - Rigid | UPVC | Polycol, Trosiplast | Tough, flexible, flame resistance, transparent or opaque, low cost | Outdoor applications (drains, fittings, gutters) |
Styrene Acrylonitrile | SAN | Luran, Arpylene, Starex | Stiff, brittle, chemical resistance, heat resistance, hydrolytically stable, transparent, low cost | Housewares, knobs, syringes |
Thermoplastic Elastomer/Rubber | TPE/R | Hytrel, Santoprene, Sarlink | Tough, flexible, high cost | Bushings, electrical components, seals, washers |
Return to top