2/28/24, 9:26 AM What is a Thermoplastic?

(Definition and Examples) - TWI

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WHAT IS A THERMOPLASTIC?
(DEFINITION AND EXAMPLES)

A thermoplastic is a class of polymer that can be softened through heating and then

processed using methods such as extrusion, injection moulding, thermoforming and blow

moulding.

Thermoplastics harden once cooled and do not show any changes in chemical property after

being heated and cooled multiple times, making them easily recyclable.

Amorphous and Semi-crystalline Thermoplastics

Thermoplastics are made by joining small molecules, called monomers, together to form long

chains using a process called polymerisation. A single polymer chain can be made from many

thousands of monomers. The atoms in a polymer chain are joined by strong covalent bonds,

whereas the forces between chains are weak.

Depending on the type of monomer, polymer chains may have side branches. If a polymer

chain has only a few, short side branches then the chains can form ordered, crystalline regions,

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called spherulites. However, if the chain has many large side branches, then it is not possible

for ordered regions to be formed and the polymer is amorphous. Examples of amorphous

polymers are polystyrene (PS), polyvinyl chloride (PVC) and acrylonitrile-butadiene-styrene

(ABS). Even for polymers with crystalline regions, there are always some amorphous regions

between the crystallites, so these polymers are called semi-crystalline. Examples of semi-

crystalline polymers are polyethylene (PE), polyamide (PA) and polypropylene (PP). For semi-

crystalline polymers, as the temperature increases, the bonds between the polymer chains

weaken to create a pliable solid and then a viscous liquid, which allows the plastic material to

be shaped to produce parts.

Amorphous plastics are used for applications where optical clarity is required since light is

scattered by crystallites. These amorphous plastics are, however, less resistant to chemical

attack and environmental stress cracking due to the lack of crystalline structure.

Before a thermoplastic polymer can be used it is normally mixed with additives, such as

stabilisers, plasticisers, lubricants, flame retardants and colourants, to improve the polymer’s

functionality, stability or appearance. For example, stabilisers are added to reduce degradation

due to sunlight or heat and plasticisers can be added to increase the mobility of amorphous

chain segments, lowering the glass transition temperature and decreasing brittleness.

Advantages

The advantages of thermoplastics include:

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Readily recyclable

Wide range of mechanical properties

Light weight compared to metals

Aesthetically-superior surface finish compared to thermosets

Good chemical resistance

Energy efficient processing

Disadvantages / Limitations

Despite the many advantages, there are also some limitations associated with thermoplastics.

Due to their low melting point compared to metals, thermoplastics are inappropriate for use

on some high temperature applications. In addition, some thermoplastics are susceptible to

creep when exposed to long-term stress loads.

Examples and applications

Thermoplastics come in a range of types with their own unique applications. Examples of

thermoplastic polymers include:

1. Polyethylene

Polyethylene is the most commonly used plastic in the world. It is in fact a family of materials

that come with a range of densities and molecular structures, each with their own applications.

Trade names include Alathon, Borstar, Dowlex, Eltex, Finathene, Hostalen, Lacqtene, Lupolen,

Rigidex and Vestolen A. Strong and resistant to most chemicals, ultra high molecular weight

polyethylene (UHMWPE) is used to manufacture moving machine parts, bearings, gears,

artificial joints and bulletproof vests. High density polyethylene (HDPE) is used to make items

such as chemical tanks, gas and water pipes, toys, shampoo bottles and margarine tubs.

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Medium density polyethylene (MDPE) is used for gas and water pipes, packaging film and pond

liners. Linear low density polyethylene (LLDPE) is used for plastic bags, shrink/stretch films and

food packaging. Being the softest and most flexible of these materials, low density

polyethylene (LDPE) is used for the manufacture of squeeze bottles, sacks and sheets.

2. Polypropylene

Polypropylene is the second most widely used commodity polymer in the world. It is used

across a wide range of industries to create items including reusable food containers, sanitary

products, heat resistant medical equipment, ropes, carpets, car batteries, cable insulation,

storage bins, and even banknotes! Trade names include Adstif, Clyrell, Hifax, Hostalen, Inspire,

Isoplen, Moplen, Novolen, and Vestolen.

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End of Life Recycling of Polypropylene

TWI coordinated the European funded, collaborative ISOPREP project, which aimed to exploit a

novel patented ionic solvent to selectively solubilise polypropylene found in waste carpet,

creating a path to the wider end-of-life recycling of polypropylene.

At the start of the project, just 1% of polypropylene was being recycled, with the rest left to go

to landfill, where it can pollute the land or sea. Recycling not only helps prevent such pollution,

but also prevents the need to produce new PP products and the associated environmental

impact that this has.

You can find out more about the ISOPREP project, here.

3. Polyvinyl chloride

Being tough, lightweight, and resistant to acids and bases, polyvinyl chloride (PVC), also known

as vinyl, is used by the construction industry for items including water pipes, drainpipes,

gutters and roofing sheets. Trade names include Astraglas, Benvic, Vestolit and Vinnolit.

PVC can also be made more flexible with the addition of plasticisers, where it is used for hoses,

tubes, electrical insulation, clothing, upholstery and inflatable products such as waterbeds and

pool toys. Trade names include, Acvitron and Lifolit.

4. Poly(ethylene terephthalate)

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Poly(ethylene terephthalate) (PET) or polyester has a good combination of mechanical and

thermal properties, chemical resistance and dimensional stability. It is used for liquid

containers, especially carbonated soft drinks, food containers and, in fibre form, for clothing. It

is the most recycled polymer worldwide. Trade names include Dacron, Eastapak, Rynite and

Terylene.

5. Polyamide

Polyamide (PA) is also known by the trade names Nylon, Akromid, Akulon, Grilamid, Grilon,

Rislan and Ultramid. It was originally used as a replacement for silk when making items such as

flak vests, parachutes and stockings. Nylon fibres are also used for fabric, carpets, rope and

strings for musical instruments. It is also used for machine screws, gear wheels and power tool

casings.

6. Polystyrene

Polystyrene (PS), also known by the trade names Styron and Vampstyr, is manufactured in

different forms that are suitable for different applications. It is used to make items such as

disposable cutlery, cases for CDs and DVDs, and smoke detector housings. Expanded

polystyrene (EPS) foam, also called by the trade name Styropor, is used for insulation and

packaging materials and extruded polystyrene foam (XPS), also called by the trade name

Styrofoam, is used for architectural models and drinking cups. Elsewhere, polystyrene

copolymers are used for the manufacture of toys and product casings.

7. Acrylonitrile-butadiene-styrene

ABS, also known by trade names Cycolac and Ensidur, is a lightweight polymer that shows high

impact resistance and mechanical toughness compared to most thermoplastics and is widely

used in everyday consumer products like toys and telephones.

8. Polycarbonate

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Polycarbonate (PC) is also known by trade names including arcoPlus, Lexan, Makroclear and

Makrolon. Easy to mould and thermoform, it is used in a range of applications in the medical,

construction, electronics, automotive and aerospace industries, including safety glasses, bullet-

resistant glass, CDs and DVDs, car headlamp lenses and safety helmets.

9. Poly(methyl methacrylate)

Poly(methyl methacrylate) (PMMA) or acrylic, is also known by the trade names Acrylite,

Altuglas, Lucite, Oroglas, Perspex and Plexiglas. It is widely used as a substitute for glass in

aquariums, aircraft windows, motorcycle helmet visors and for the lenses on exterior

automobile lights. Acrylic is also used for signage, for eye lenses and in bone cement for

medical use, and also in paint, where PMMA particles are suspended in water.

10. Polyoxymethylene

Demonstrating a high stiffness, good dimensional stability and low friction, polyoxymethylene

(POM), also known as acetal, polyacetal and polyformaldehyde, is used for parts that require

high precision, such as bearings, valve parts, gears and electrical components, and is also

known by the trade names Celcon, Delrin, Duracon, Hostaform, Kepital, and Ramtal.

11. Poly(lactic acid)

Derived from renewable resources like sugar beet pulp, corn starch, chips, sugarcane and

tapioca roots, poly(lactic acid) (PLA) is a compostable thermoplastic. It is used in tableware,

food packaging and additive manufacturing (3D printing). Trade names include Bio-Flex, Fozeas

and Ingeo.

12. Poly(phenylene oxide)

Poly(phenylene oxide (PPO) offers a range of attractive properties, including high impact

strength, heat distortion, and chemical stability against mineral and organic acids. It also offers

low water absorption, but can be difficult to use due to the high processing temperature.

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Commercial resins, such as Noryl, blend PPO with high impact polystyrene (HIPS) to lower the

processing temperature, making it easier to process. Applications include electrical

components and washing machine parts.

13. Polytetrafluoroethylene

Polytetrafluoroethylene (PTFE) belongs to a class of thermoplastics known as fluoropolymers,

and is also known by the trade names Teflon, Dyneon, Fluon and Hostaflon. It has one of the

lowest friction coefficients of any known solid and is well-known for its use on non-stick

cookware. It is also used as a lubricant to reduce frictional wear between sliding parts like

gears, bearings and bushings. Because it is chemically inert, it is also used for pipes and

containers that come into contact with reactive chemicals.

14. Poly(vinylidene fluoride)

Poly(vinylidene fluoride) (PVDF) is another member of the fluoropolymer family. It is also

known by the trade names Kynar, Hylar and Solef, and is known for its chemical inertness and

resistance, used for engineering sheets and pipes as well as to make powders and coatings.

PVDF is also widely used in the chemical industry for piping to transport aggressive chemicals

and high purity liquids.

15. Polyetheretherketone

Polyetheretherketone (PEEK) is a high-performance thermoplastic used for a range of

engineering applications, including bearings, pumps, valves and medical implants, due to its

good abrasion resistance and low flammability as well as low emission of smoke or toxic gases.

Trade names include Victrex and Vestakeep.

16. Poly(phenylene sulphide)

Poly(phenylene sulphide) (PPS) delivers superb chemical resistance, electrical properties, flame

retardance, and transparency to microwave radiation as well as a low coefficient of friction.

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These properties mean that, when injection or compression moulded at temperatures high

enough to create crosslinks, PPS can also be used to make cookware, bearings and pump

components suitable for corrosive environments. Trade names include Torelina and Ryton.

17. Polyetherimide

With a high heat distortion temperature, modulus and tensile strength, polyetherimide (PEI) is

used in high performance electronic and electrical parts, including for the automotive industry,

as well as in consumer items like microwave cookware. Trade names include Ultem.

18. Polyethersulfone

Polyethersulfone (PESU, PES) has high hydrolytic, oxidative, and thermal stability as well as a

good resistance to alkalis, salt solutions, acids from aqueous minerals, oils and greases.

Application include medical components, gas separation membranes and freezer-to-

microwave food containers. Trade names include Ultrason and Veradel.

19. Polybenzimidazole

Polybenzimidazole (PBI), also known by trade names including Celazole and Duratron, has

a very high melting point compared with other thermoplastics and shows excellent chemical

and thermal stability. PBI’s superb stability, retention, stiffness and toughness at high

temperatures has lent it to being used for firefighting clothing, space suits for astronauts,

protective gloves, welding apparel, wall fabrics for aircraft and for membranes in fuel cells.

FAQs

Are Thermoplastics Recyclable?

Thermoplastics are easily recyclable as the polymer chain does not degrade when heated.

Because the chemical bonds within the chain remain intact while the weaker bonds between

polymer chains break down, thermoplastics can be melted and re-used repeatedly.

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Are Thermoplastics Safe?

Most types of thermoplastic are safe to use as intended. However, there have been concerns

raised over PVC because of the vinyl chloride monomer (VCM) that is used in production.

However, modern manufacturing methods mean that the release of VCM is very low while the

residual VCM left in the polymer is so low that it can’t be detected.

Are Thermoplastics Biodegradable?

Most thermoplastics are not biodegradable. However, some thermoplastics, such as poly(lactic

acid) (PLA), poly (vinyl alcohol) (PVAL, PVOH) and polyhydroxyalkanoates (PHAs) are.

Are Thermoplastics Brittle?

Below their glass transition temperature (Tg), thermoplastics are brittle and deform by elastic

deformation. However, when above their Tg, thermoplastics are ductile and deform mainly

through plastic deformation. So, in short, thermoplastics go from brittle to ductile as they are

heated through their Tg.

Can Thermoplastic be Remoulded?

Thermoplastics can be remoulded repeatedly by heating and then reforming them into new

shapes.

Can Thermoplastic Melt?

Semi-crystalline thermoplastics melt at a particular temperature when their crystalline regions

transition to a random arrangement. This melting point is different for different

thermoplastics. Amorphous thermoplastics do not have an ordered structure and therefore do

not melt; they have a glass transition temperature, below which the material is brittle and, as

the temperature increases, the material softens and becomes more rubbery.

Can Thermoplastic be Painted?

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Thermoplastics can be painted to provide a different surface finish. However, you will need to

use the correct type of paint so that it doesn’t react with any polymer coating and cause

discolouration and lowering weather resistance. Acrylic based paints, including spray paints,

are a good option for painting thermoplastics.

Can Thermoplastics be Welded?

Thermoplastics can be welded using a variety of different techniques. You can find out more

about welding thermoplastics here.

Conclusion

Thermoplastics are polymers that can be softened through heating before being processed

and then left to cool and harden. Once cooled, they show no changes in chemical properties,

meaning they can be re-melted and re-used several times.

There are many types of thermoplastic, each with their own distinct applications and

properties, including being non-stick, tough, flexible, and so forth.

Thermoplastics are synthesised from a range of different materials, including renewable and

biodegradable resources such as sugar beet, and have uses in industries including

construction, aerospace, automotive, electronics, rail, oil and gas, and power, as well as for a

huge range of domestic and consumer products.

TWI

TWI provides our Industrial Members with support in using a wide range materials, including

thermoplastics. Our expertise includes testing different plastics and composites as well as

materials selection and joining methods for polymeric materials used in different applications.

TWI is an Industrial Membership based organisation. TWI's experts can provide your company

with an extension to your own resources. Our experts are dedicated to helping industry

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