Thermoplastic materials

List of the most common thermoplastics used in injection molding.

1. Polyethylene (PE)
This is one of the best-known thermoplastics, known outside manufacturing and engineering
circles for its versatility as a packaging product.
It has a variable crystalline structure that allows for a vast range of applications. This
thermoplastic can be classified as either high-density polyethylene (HDPE) or low-density
polyethylene (LDPE).
Both variants have high tensile strength, impact resistance, moisture resistance and
recyclability. Higher density versions tend to be more rigid and heat resistant, making it
suitable for,
 bottles
 food containers
while the lower density alternative tends to be used more for,
 plastic bags
 and films.
2. Polycarbonate (PC)
Polycarbonate (PC) plastics are a naturally transparent amorphous thermoplastic. Although
they are made commercially available in a variety of colors (perhaps translucent and
perhaps not), the raw material allows for the internal transmission of light nearly in the
same capacity as glass. This thermoplastic comes into its own when a strong, transparent
material is required. It also has excellent impact resistance, making it suitable for,
 bullet-proof glass
 reinforced greenhouse panels
It can undergo high levels of stress without cracking or breaking. Other uses for
polycarbonate include,
 DVD discs,
 eyewear lenses and
 mobile phone components
Polycarbonate is easily worked, moulded and thermoformed, making it a popular material in
the construction industry. They are ideal for,
 greenhouse panels,
 conservatory roofing and
 porch or outhouse windows
3. Acrylic
Acrylic is popular for its attractive finish and its versatile nature. It can be moulded in a
wide variety of colours too. Acrylic is rigid with strong impact resistance. Acrylic is a
transparent plastic material with outstanding strength, stiffness, and optical clarity. Acrylic
sheet is easy to fabricate, bonds well with adhesives and solvents, and is easy to
thermoform. It has superior weathering properties compared to many other transparent
plastics. Acrylic sheeting can often be used as an alternative to glass in such applications as,
 windows
 fish tanks
 aquariums
 motorcycle helmet visors
It is also frequently used as a material for arts and crafts projects, due to its transparency
and aesthetic appeal. Other uses include shop signage and automotive lighting, due to its
high resistance to adverse weather conditions and ease of cleaning and maintenance.
4. Polyamide
Polyamide is better known as nylon and is a common material used in fabrics and sports
equipment such as nets. It is extremely tough and resistant to wear and tear. Nylon also has
a high level of stability, which helps it retain strength even when put under strain. It is
highly resistant to other external forces too, including abrasion, chemical corrosion and
impact. Nylon is a generic designation for a family of synthetic polymers composed of
polyamides (repeating units linked by amide links). Nylon is a silk-like thermoplastic,
generally made from petroleum that can be melt-processed into fibers, films, or shapes. As
well as clothing, nylon is also used in a wide range of applications, including,
 sports equipment
 footwear
 medical products
 industrial components and within the automotive sector
Examples of naturally occurring polyamides are proteins, such as wool and silk.
5. Polystyrene (PS)
High Impact Polystyrene is very popular, thanks to its tough nature and resistance to
impacts and heavy knocks. It is created by modifying crystal styrene with rubber, which
gives it its impressive resistance to impacts. It is often used to protect assets, such as parcels
in transit or valuable machinery and is low cost and easy to produce. It is non-toxic and so
can be produced to fit FDA grades and be used as containers for consumable goods. While
polystyrene is flammable, flame-retardant versions can be produced, along with high gloss
grades that give a top-quality finish. Polystyrene (PS) is principally used in solid, foam, and
expanded polystyrene (EPS) forms.
5. Polypropylene (PP)
Another common thermoplastic, polypropylene (PP) is very flexible, rendering it perfect for
such applications as athletic clothing, rugs and car parts that need to be bent into position.
Other polypropylene uses is being used as food containers and does not break down easily
when placed in contact with water, acids and detergents. So, it can be reused multiple times,
reducing waste and resulting in a more eco-friendly product. Polypropylene has a high
melting point and high resistance to cracking and stress. It has been compounded for a wide
range of products and is extremely versatile.
6. Acrylonitrile Butadiene Styrene (ABS)
This opaque thermoplastic is a terpolymer, made up of three polymers, acrylonitrile,
butadiene and styrene. The combination produces a flexible, very light material that can be
moulded into a plethora of everyday items and components for use in everyday life. A few
of ABS plastic properties is that it can be modified to produce the exact levels of impact
resistance, toughness and heat resistance that the manufacturer needs by moulding it at a
high or low temperature. ABS is used commonly in drainpipe systems, automotive parts ,
musical instruments and sporting equipment, such as,
 golf club heads
 tennis rackets
7. Polyester
Another commonly known thermoplastic , used frequently in the production of clothing, bed
wear and other household fabrics. However, polyester is also used in electrical,
medical, automotive and packaging applications. Polyester (polyethylene terephthalate)
is derived from a chemical reaction involving petroleum, air, and water. This artificial fiber
is comprised of purified terephthalic acid (PTA) and monotheluene glycol (MEG). Polyester
is thermoplastic, meaning it can be melted and reformed. Industrial uses include,
 ropes
 yarns,
 conveyor belt fabrics
 seat belts
 coated fabrics
 tarpaulins
 plastic reinforcements
Polyester offers excellent chemical resistance, dimensional stability and a high toughness-
stiffness balance. Polyester fabrics are also highly stain resistant. However, it can also be
subject to moisture susceptibility and poor thermal qualities, which can make drying times a
critical concern.
Examples of Thermosetting Plastic
Thermosetting plastics are widely used in various industries due to their high thermal stability
and chemical resistance properties. We can mold them into any shape, and once they set, they do
not lose their stability even in extreme temperature conditions. Many manufacturers have
switched to thermosets as they are cost-effective and are a great replacement for some metal
components. Here are some examples of thermosetting plastics.
1. Vulcanized Rubber
Vulcanized rubber is a type of thermoset plastic as once it is molded, it retains its shape and can’t
be recycled again. The untreated rubber is converted into the vulcanized rubber through a
process called vulcanization. In this process, the natural rubber is treated with Sulphur and
various activators like Zinc fatty acid esters at the temperature of 140-160°C. Vulcanized rubber
is more hardened than natural rubber. It is used in the manufacturing of various goods as it has
both electrical and thermal insulation properties. Moreover, it has good abrasion properties and is
inexpensive. It is used in manufacturing tires of vehicles because it has high tensile strength,
hence it reduces the chances of tire punctures. Other uses of vulcanized rubber include seat belts,
toys, conveyor belts, rubber hoses, and shoe hoses.
2. Bakelite
Bakelite was the first thermoset plastic that was synthesized from synthetic components. The
chemical name of Bakelite is ‘Polyoxybenzyl Methylene Glycol Anhydride,’ and its chemical
formula is (C6 H6O.CH2O)n. Commercially, it is also known as phenol-formaldehyde resin as it
is synthesized by the condensation process between phenol and formaldehyde, under high
pressure with HCl as a catalyst. However, other catalysts like ammonia and zinc chloride are also
used sometimes, as per the requirement of the reaction. The product obtained from this reaction
is further heated slowly till a hard substance called Bakelite is obtained. Bakelite is easily
moldable in its liquifiable state, hence it is used in the manufacturing of various products. To
increase the strength of the bakelite, various fillers like gypsum, mica, asbestos are also used.
Bakelite has a wide application in the electrical industries for making switches, boards, sockets,
and wire insulation because of its electrical insulation properties. The unique property of
Bakelite is that it can be produced in different colors that is why it is widely used in the
manufacturing of colorful bangles, bracelets, and artificial jewelry. The application of Bakelite is
also found in various kitchenware products.
3. Duroplast
Duroplast is a composite thermoset material that is similar to Bakelite except for the fact that it is
reinforced with cotton or wool fibers. One of the most significant properties of Duroplast is that
it is lightweight and strong. Due to this property, Duroplast is used in making car bodies, which
reduces the cost of using steel for making various car parts. It is also used in the manufacturing
of toilet seats. However, it has a major disadvantage, which is its difficulty to decompose. If we
burn them, they release highly toxic fumes that are harmful to the environment.
4. Urea-Formaldehyde Resins
Urea-Formaldehyde is also known as Amino plastic or carbamide-methanol. As the name itself
suggests, they are synthesized by the reaction between the Urea and Formaldehyde in the
presence of water, and at a PH value higher than 7. These Thermosets are highly cross-linked
and have a semi-crystalline structure. They become rigid very rapidly if the temperature is
elevated. They have wide applications in wood product industries and are used as an adhesive for
particleboard. Their other applications include laminating decorative items, coating, air filtration,
and fiberglass mats.
5. Melamine-Formaldehyde Resins
They are synthesized by reacting Melamine with Formaldehyde under low alkaline conditions.
Like urea-formaldehyde resins, it is also widely used in wood industries. Melamine polished
boards have better heat and chemical resistance properties than natural boards. Melamine-
Formaldehydes are fully compatible with Urea-Formaldehyde resins and are often reacted with
each other for reducing the emission of formaldehyde from particleboards, and this blend of
resins is called melamine-urea-formaldehyde. Melamine resins are fire-retardant that is why they
are used as additives in the manufacturing of papers, paints, plastics, and flame-resistant textiles.
Many other products that are manufactured using these resins are particleboards, laminates,
kitchenware, and floor tiles.
6. Epoxy Resins
Epoxies are reactive thermosetting resins and are also known as polyepoxides. Epoxy resins
contain at least one epoxide group. The most commonly used epoxies are ‘Diglycidyl Ether of
Bisphenol A’ (DGEBA) and ‘Diglycidyl Ether of Bisphenol F’ (DGEBF). However, DGEBF is
somewhat on the expensive side. Epoxy resins are widely used in aerospace industries because of
their heat and corrosion-resistant properties. These resins also find use in structural adhesives,
metal coatings, and encapsulations of electrical components.
7. Polyimides
Polyimide resins are produced by the condensations reaction of aromatic primary diamines with
aromatic tetracarboxylic dianhydrides. Because of the presence of aromatic rings in them, they
have excellent thermal and chemical properties, and they can withstand high temperatures. They
are widely used in the production of sockets, bushings, and bearings as they exhibit high
mechanical strength and are water-resistant. They are also a great replacement for high-
performance materials like metals and ceramics. However, their one shortcoming is that they are
quite expensive.
8. Silicon Resins
Silicon resins have many applications due to their strong 3D network structure. They have the
general formula RnSiXmOy, where R is usually Methyl or Phenyl, and X is the functional group
(H, OH, Cl) or Alkoxy group (OR). These resins form very hard, heat and water resistance films,
and show outstanding dielectric properties. They also provide very good UV rays resistance
films. Silicon resins are available in different consistencies from a range of highly viscous
liquids to solids. They find their applications in paints, coatings, sealants, silicone fluids, and
electrical industries due to their reliability and durability. Silicon resin is widely used in art and
craft for making various silicon items. They are also used in the healthcare sector because of
their biocompatible nature.
9. Cyanate Esters
Cyanate esters consist of -O-C=N group attached to a phenyl ring. They show low water
absorption, low dielectric loss, and high-temperature stability than Epoxies. Cyanate esters are
usually found in brittle form, which is why they are often blended with epoxy resins or other
thermosetting resins to get better-toughened products of enhanced properties. They are mainly
used in aerospace industries due to their high structural and mechanical properties. Moreover,
they are also used for electronic chip adhesives and encapsulation of various electronic
equipment.
10. Polyurethane
Polyurethanes are produced by the reaction between the organic diisocyanate and a diol
compound. They can also be produced in the foamed structure if water is used in their
manufacturing process. This foamed structure is used in the manufacturing of cushions, carpets,
armrests, and mattresses. Polyurethane has a rigid foam structure, and they are used as insulation
for various buildings. Their elastomeric structure finds applications in making car bumpers,
steering wheels, windshields, gaskets, door panels, and other automotive and electrical
components. However, their main disadvantage is that they are prone to microbial attacks and
often get yellow underexposure to UV light.
11. Furan Resins
Furan structure consists of a five-membered aromatic ring having four carbon (C) atoms and one
Oxygen (O) atom. Furan resins have thermoset oligomers (Oligomers are the polymers whose
molecules have similar repeating units), these oligomers are cross-linked together when heated in
the presence of a catalyst. These resins are highly volatile, having boiling points near to room
temperature, and they are soluble in some organic solvents like ether, acetone, and alcohol. Furan
resin is widely used in cement and binders to make them chemical resistant. Their other uses
include wood adhesives, coatings, and explosive binders. The main disadvantage of furan is that
it is highly toxic to human beings.
12. Vinyl Ester Resins
Vinyl ester resins are prepared by the process of esterification of epoxy resin with vinyl acids;
the vinyl acid group is responsible for the cross-linkage in them. It is ideal for the vacuum
infusion process as it has low viscosity, hence it is easy to pour. Vinyl ester resins are often
called the hybrid of Epoxy resins and polyester because their properties or other characteristics
lie between them. It is widely used in the marine industry because of its high water-resistant and
corrosion-resistant properties. They are widely used for corrosive-resistant coatings in tanks and
pipes. They also find their application in chemical plants and petrochemical industries because of
their high heat resistance level.
13. Polyester Resins
Unsaturated Polyester resins are formed by the reaction of difunctional organic acids (phthalic,
maleic, fumaric) with polyhydric alcohol (Ethylene glycol, propylene glycol, halogenated glycol)
in the presence of a catalyst. They are resistant to water and various chemicals and can withstand
very high temperatures. They are used in boat building industries for making various parts of
yachts and workboats because of their high strength and durability. Nowadays they are also used
for flat roofing because they provide seamless and easy to maintain flat roofs. These resins also
find application in making various electrical components, pipes, tanks, and ducts because they
are lightweight, easy to handle, and have a longer shelf life.
Thermoplastic Materials:
 Acrylic
 Polycarbonate
 Nylon
 Polyvinyl Chloride (PVC)
 Polypropylene
 Polyethylene
Thermoplastics are used to create everything from milk jugs and food packaging to toys, car
dashboards, and bathtubs!
Thermoset Materials:
 Polyester
 Silicone
 Melamine
 Polyurethane
 Epoxy
 Urea formaldehyde
Thermosets are used to create hard, protective coatings, strong fibers, and even things like
dinnerware.
Benefits of Thermoplastics
 Can be recycled
 Generally very resistant to corrosion, impact, and chemical exposure
 Many types are food-safe
 Highly customizable and can have anti-static coatings, anti-microbial finishes, and other
coatings, paint, and texture added.
 Can be remolded and reshaped
 Can be blended with rubber or other fillers for strength, flexibility, and other features.
 Can be shaped through thermoforming or injection molding
Because of their benefits, thermoplastics are much more versatile than thermoset materials, able
to be formed into almost any shape and because they can be recycled, are more eco-friendly to
manufacture.
Benefits of Thermoset Materials
 Very hard and rigid
 Highly stable
 Resistant to high temperatures
 Can be reinforced with Kevlar, carbon, or fiberglass
While the chemical makeup of thermosets mean they can’t be recycled, they are a very long-
lasting plastic due to their heat resistance and structural integrity.
Examples of Composite Materials
1. Mud Bricks
What better way to introduce composites than to talk about mud bricks. Mud bricks came to be
when people realized that straw was resistant to stretching and that dried mud copes well with
compression.
The ancient Egyptians used a composite of clay mixed with straw. Developing countries use mud
bricks to build their huts. Perhaps the introduction of the mud-brick is what inspired much more
advanced composites.
2. Wood
Wood (and trees, of course) have been around for thousands of years. Yet, you might be
surprised to find out that wood is actually a composite. Wood is made of long fibers of cellulose
that are held together by a weaker substance called lignin.
The organization of the cellulose within the wood is what makes some types of wood (like
ironwood) stronger than others. Engineered wood, such as plywood, takes advantage of weaker
woods by cutting them into thin pieces and then gluing them together. This gives plywood the
flexibility and the softer qualities that allow for nailing into plywood.
3. Fiberglass
Fiberglass is simply plastic that is combined with glass fibers. It is likely that your bathtubs,
doors, decking, and window frames all take advantage of fiberglass in some way.
Fiberglass is particularly useful in windows since the fiberglass and glass windowpane shares an
almost identical coefficient of expansion, meaning that hot and cold temperatures let
your entire window expand and contract as one piece.
4. Translucent Concrete
Concrete is a primitive example of composite material because of the combination of small rocks
and cement that it holds. When optic fibers, similar to those found in fiberglass, are added to
concrete, you get translucent concrete. The look and feel of the concrete can vary depending on
the ratio of cement to optic fibers.
5. Absorbent Concrete
Absorbent concrete may seem like something straight out of a comic book but while it does seem
impossible, there’s actually a decent bit of science to back it up.
Absorbent concrete works by allowing water (and other viscous liquids) to seep through large
pebbles and into another layer of rubble. This type of concrete can prove to be useful in dealing
with flooding once implemented on a large scale.
6. Kevlar
While Kevlar is not a composite in itself, it is often used as a part of composite materials. This is
because of Kevlar’s extremely high tensile strength, meaning that it can resist stretching quite
well. Kevlar’s compressive strength is about 1/10 of its tensile strength, and that’s why it is
combined into composites.
Airplanes, boats, bicycles, motorcycle clothing, and Nike shoes all take advantage of Kevlar’s
remarkably high tensile strength.
7. Carbon Fiber
Carbon fiber is often combined with plastics into what is called carbon fiber reinforced polymer.
These compounds are used in airplane wings, automobile body parts, and sports equipment.
Benefits of carbon fiber include, but are not limited to, high stiffness and strength, lightness,
corrosion resistance, and a low coefficient of thermal expansion (meaning that it doesn’t expand
or contract very well).
8. Pykrete
Ice and wood are adequately strong in their own ways but when combined together, they form a
composite called Pykrete. Pykrete (also known as bulletproof ice) is a combination of ice and
wood pulp that can be up to 14 times stronger than ice.
9. Composite Honeycomb
This is a broad category of composites that all share the same characteristic of a honeycomb
design. Man-made composite honeycomb is useful because of its high compressive and shear
strength. Honeycomb designs can make products cheaper since less material is required to
achieve the same desired strength.
10. Engineered Bamboo
Plywood, bamboo strips, and glue can be combined to create engineered bamboo flooring.
Bamboo’s high tensile strength, hardness, and lightweight nature make it desirable when
combined into a composite flooring material.
In fact, temporary bamboo huts were constructed for victims of the 2004 Indian Ocean tsunami.
This just comes to show how useful bamboo can be in lightweight construction applications.
There’s More!
Hundreds, if not thousands, of examples of composite materials, exist in today’s world.
Applications in the medical, aerospace, automotive, and military fields exist in abundance.
Benefits of Composites
Composites have permeated our everyday lives: They are used in the cars we drive, golf clubs
we swing, pipes that remove wastewater from our neighborhoods and much more. Some
applications, such as rocket ships, probably wouldn’t get off the ground without composite
materials. Composites offer many benefits. Key among them are strength, light weight, corrosion
resistance, design flexibility and durability.
Strong: Per pound, composites are stronger than other materials such as steel. The two primary
components of composites – fibers and resins – contribute to their strength. Fibers carry the load,
while resins distribute the weight throughout the composite part as required.
Lightweight: Composites are light in weight compared to most woods and metals. But why is
lighter better? Lower weight contributes to fuel efficiency in cars and airplanes. And lighter
objects, ranging from utility poles to bridge decks, are easier to transport and install.
Resistant: Composites resist damage from weather and harsh chemicals that can eat away at
other materials. That makes them good choices for applications that face constant exposure to
salt water, toxic chemicals, temperature fluctuations and other severe conditions.
Flexible: A wide range of material combinations can be used in composites, which allows for
design flexibility. The materials can be custom tailored to fit unique specifications of each
application. Composites also can be easily molded into complicated shapes.
Durable: Simply put, composites last! Structures made with composites have a long life and
require little maintenance. Many products made with composites, such as boats, have been in
service for more than half a century.
Natural vs Synthetic Polymers
There are two types of polymers: synthetic and natural. Synthetic polymers are derived from
petroleum oil, and made by scientists and engineers. Examples of synthetic polymers include
nylon, polyethylene, polyester, Teflon, and epoxy. Natural polymers occur in nature and can be
extracted. They are often water-based. Examples of naturally occurring polymers are silk, wool,
DNA, cellulose and proteins.