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    Can you modify a polymer grade safely ?

    Can you modify a polymer grade safely ?

    One of the exciting attributes of polymers is that the properties of any polymer can be modified by tinkering with the basic molecular structure or incorporating a range of additives.  However you have to be aware that altering one property may have a knock-on effect on other properties.

    I recall one example where the designer was trying to push wall thicknesses down to 0.7 mm.  (This was in the days when 1 mm was considered daring).  As you can imagine mould filling proved a headache with the chosen material, polycarbonate.  The material supplier offered a low molecular weight grade, with lower melt viscosity and better mould filling.  Unfortunately this grade had a slightly reduced impact resistance and did not pass the stringent impact test for the product.

    To solve this problem? The material supplier added an impact modifier (a rubbery polymer) to restore impact strength, without affecting mould filling.  Everything in the garden looked rosy.

    Unfortunately they did not anticipate the moulder edging up the melt temperature beyond the recommended limit, to squeeze fractions from the cycle time and improve his margins.  He had applied this tactic with standard polycarbonate grades without any negative outcome. However, the impact modifier did not enjoy the dwell in the hot runner system at the higher temperature and incurred incipient degradation.  Although the mouldings looked no different cosmetically and met the impact standards, trouble lay ahead during service with embrittlement and stress cracking.

    The moral is to check that modifying one property does not lead to unwelcome consequences in another property.

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    Coping with weld lines

    In injection moulding, weld lines (knit lines) form when two melt fronts meet. If the melt fronts do not coalesce completely, at best there will be a cosmetic flaw. At worst there will be a mechanical weak-spot, with strengths of the order of 10 - 90 % of the material potential.

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    What determines friction between thermoplastic components?

    Friction is an important property for thermoplastics in bearings and gears but also has a part to play in assembly of plastic parts (snap-fit and interference-fit) and ejection during moulding.

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    Polypropylene: the Workhorse of the Plastics Industry

    Polypropylene. Little did Karl Zeigler or Giulio Natta realise, 60 years ago, when they were developing a catalyst system to produce a useful thermoplastic from the inexpensive monomer, propylene, that their work would have such far reaching consequences.

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    What makes medical grade plastics so special?

    Toughness and transparency are important properties for the constituents of intravenous lines.

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    The Long and the Short of Fibre Reinforcement of Thermoplastics

    Fibre Reinforcement. The advantages of adding glass fibre to thermoplastics to increase stiffness (modulus), strength, heat distortion resistance and dimensional stability are well known.

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    What causes mouldings (and moulders) to be off-colour?

    When mouldings are not the intended colour, the first thing to check is the raw material, particularly the dosing rate, if you are using masterbatch, and the quality of regrind.

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    Transparent ABS can be a clear winner

    Transparent ABS. Mentioning transparency in the context of ABS moulding materials can raise a few eyebrows. This is because ABS is normally taken to be opaque and indeed the vast majority of grades of ABS are opaque.

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    Understanding the difference between SBS & SEBS thermoplastic elastomers?

    The difference between SBS and SEBS thermoplastic elastomers explained.

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    Is MFR really much help to moulders these days ?

    Often a moulder has to change material grades. One of the first properties to be consulted on the new data sheet is usually the MFR. This is to establish if the new grade has the same melt viscosity performance.

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    What gives Moulders a Warped View on Life?

    Warping is one of the most frustrating injection moulding faults. This is because it does not always appear immediately, the causes are complex and prevention is difficult.

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