How do you choose the Perfect Thermoplastic for your product?
A Comprehensive Guide
Choosing the correct thermoplastic for a product involves evaluating several key factors to ensure optimal performance, cost-effectiveness, and manufacturability. These considerations include several different dimensions: mechanical properties, thermal properties, chemical resistance, electrical properties, the aesthetic and functional requirements, environmental factors, ease of processing and cost, and regulatory compliance.
So, let’s take a closer look at these factors in more detail.
Thermoplastic Mechanical Properties
When we talk about mechanical properties, first of all we look at strength and durability, and assess the tensile, impact, and flexural strength needed for the product to withstand intended use and potential stresses. For heavy-duty applications, materials like polycarbonate (PC) or acrylonitrile butadiene styrene (ABS) might be suitable. Then we also need to look at the flexibility or rigidity. Thermoplastics like polyethylene (PE) or thermoplastic elastomers (TPE) offer flexibility, while materials like polyphenylene sulfide (PPS) provide rigidity.
What about Thermal Properties?
Thermal properties are also a critical factor. When it comes to heat resistance, products that are exposed to high temperatures require materials with high glass transition or melting points, such as polyetheretherketone (PEEK) or polysulfone (PSU).
Environmental Factors of Thermoplastics
Chemical resistance should be taken into consideration when looking at the environments the product will face, for exposure to oils, acids, or solvents, materials like polypropylene (PP) or fluoropolymers (e.g. PTFE) provide excellent resistance. Other environmental factors to be considered include UV stability where for outdoor products UV-resistant materials like ASA or UV-stabilised polyethylene may be required; and moisture resistance so the material you select does not absorb, but instead effectively repels water.
When it comes to electrical insulation or conductivity needs, assess properties like dielectric strength. Polyvinyl chloride (PVC) is common in electrical components.
Will it work aesthetically and functionally?
The aesthetic and functional requirements of your product will mean you need to evaluate surface finish, transparency, or colour customisation. For example, polymethyl methacrylate (PMMA) offers excellent clarity for optical applications, while ABS can be easily moulded into intricate shapes.
Costs and processing of polymer types
Critically, cost is a key decision-making factor where ease of manufacturing will impact upon production costs. Some thermoplastics are easier to mould, extrude, or machine while commodity plastics like PE and PP are more cost-effective than engineering plastics like PEEK.
What about sustainability options?
Increasingly recyclability is being taken into consideration to support sustainability goals and this may guide you towards recyclable or biodegradable options, but you must take into account supply delays, challenges and potentially a higher price point.
And, of course, regulatory compliance
Finally, regulatory compliance is vital, particularly for products in medical, food, or aerospace industries which must meet specific standards, such as FDA or UL certifications.
By balancing a combination of all these considerations, designers can select a thermoplastic that aligns with product performance, environmental conditions, budget, and compliance requirements.
If you need help to choose the perfect thermoplastic, valuable technical support or advice on product specifications, our team will be delighted to hear from you: contact us. And don’t forget to follow us on LinkedIn for products insights and industry updates!
