The word plastics is from the Greek word Plastikos,

meaning “able to be shaped and molded”

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 Why Design with Plastics?
• Light weight, high weight to • Relatively low cost compared
strength ratio, particularly when to metals and composites
reinforced

Density Cost
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 Why Design with Plastics?
• Corrosion resistance
• Low electrical and thermal conductivity, insulator
• Easily formed into complex shapes, can be
formed, casted and joined.
• Wide choice of appearance, colors and
transparencies

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 Disadvantages of using Plastics

• Low strength
• Low useful temperature range (up to 600 oF)
• Less dimensional stability over period of time
(creep effect)
• Aging effect, hardens and become brittle over time
• Sensitive to environment, moisture and chemicals
• Poor machinability

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 Mechanical Properties of Various Plastics

Steel: 350 to 1900 MPa Brass: 200 to 850 MPa

Aluminum: 100 to 550 MPa
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 Polymers
• The earliest synthetic polymer was developed in 1906, called Bakelite.

• The development of modern plastics started in 1920s using raw

material extracted from coal and petroleum products (Ethylene).
Ethylene is called a building block.

• Polymers are long-chain molecules and are formed by polymerization

process, linking and cross linking a particular building block (monomer, a
unit cell).

• The term polymer means many units repeated many times in a

chainlike structure.

• Most monomers are organic materials, atoms are joined in covalent

bonds (electron-sharing) with other atoms such as oxygen, nitrogen,
hydrogen, sulfur, chlorine,….

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 The structure of polymers

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 Classification of polymers
There are two major classifications of polymers

Thermoplastics
As the temperature is raised above the melting point, the secondary bonds
weaken, making it easier to form the plastic into any desired shape. When
polymer is cooled, it returns to its original strength and hardness. The process
is reversible. Polymers that show this behavior are known as thermoplastics.

Thermosetting Plastics (thermosets)

Thermosetting plastics are cured into permanent shape. Cannot be re-melted to
the flowable state that existed before curing, continued heating for a long time
leads to degradation or decomposition. This curing (cross-linked) reaction is
irreversible. Thermosets generally have better mechanical, thermal and
chemical properties. They also have better electrical resistance and dimensional
stability than do thermoplastics.

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 Polymer’s Structures
Bonding – monomers are linked together by covalent bonds, forming a
polymer chain (primary bonds). The polymer chains are held together by
secondary bonds. The strength of polymers comes in part from the
length of polymer chains. The longer the chain, the stronger the polymer.
More energy is needed to overcome the secondary bonds.

Linear polymers Branched polymers

A sequential structure resulting in Side branch chains are attached to the

thermoplastics like nylon, acrylic,
polyethylene. A linear polymer
may contain some branched and
cross-linked chains resulting in
change in properties.
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main chain which interferes with the
relative movement of the molecular chains.
This results in an increase in strength,
deformation resistance and stress cracking
resistance. Lower density than linear chain
polymers.
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 Polymer’s Structures
Cross-linked polymers
Three dimensional structure, adjacent chains are linked
by covalent bonds. Polymers with cross-linked chains
are called thermosetting plastics (thermosets), epoxy
and Silicones.
Cross-linking is responsible for providing hardness,
strength, brittleness and better dimensional stability.

Network polymers
A three dimensional network of three or more
covalent bonds. Thermoplastic polymers that have
been already formed could be cross-linked to
obtain higher strength. Polymers are exposed to
high-energy radiation.

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 Additives in Plastics
Additives are added to polymers in order to obtain or improve certain
properties such as strength, stiffness, color, resistance to weather
and flammability.

Plasticizers are added to obtain flexibility and softness, most

common use of plasticizers are in PVC.

Ultraviolet radiation (sunlight) and oxygen cause polymers to become

stiff and brittle, they weaken and break the primary bonds. A typical
treatment is to add carbon black (soot) to the polymer, it absorbs
radiation. Antioxidants are also added to protect against
degradation.

Fillers such as fine saw dust, silica flour, calcium carbide are
added to reduce the cost and to increase harness, strength,
toughness, dimensional stability,…..

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 Additives in Plastics
• Colorants are added to obtain a variety of colors. Colorants are
either organic (dye) or inorganic (pigments). Pigments provide
greater resistance to temperature and sunlight.

• Flame retardants such as chlorine, phosphorus and bromine, are

added to reduce polymer flammability. Teflon does not burn and
nylon and vinyl chloride are self-extinguishing.

• Lubricants such as mineral oil and waxes are added to

reduce friction.

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 Applications of Thermoplastics
Design requirement: strength

Applications: Valves, gears, cams, pistons, fan blades, …

Plastics: nylon, acetal (delrin), polycarbonate, phenolic

Design requirement: wear resistance

Applications: bearings, gears, bushings, wheels, ….

Plastics: nylon, acetal (delrin), polyurethane, phenolic, polymide

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 Applications of Thermoplastics
Design requirement: functional and decorative

Applications: knobs, handles, cases, moldings, pipe fittings, …

Plastics: ABS, acrylic, polyethylene, phenolic, polypropylene, polystyrene

Design requirement: functional and transparent

Applications: lens, goggles, signs, food processing equipment, …

Plastics: acrylic, polycarbonate, polystyrene, polysulfone

Design requirement: hollow shapes and housings

Applications: pumps, helmets, power tools, cases, …

Plastics: ABS, polyethylene, phenolic, polypropylene, polystyrene, polycarbonate

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 Popular Plastics
Polyethylene (LDPE (low density) and HDPE (high density)
Properties: good chemical and electrical properties, strength
depends on composition

Applications: bottles, garbage cans, housewares, bumpers, toys, luggage

Acetal (Delrin)
Properties: good strength, good stiffness, good resistance to heat,
moisture, abrasion and chemicals

Applications: mechanical components; gears, bearings, valves, rollers,

bushings, housings

ABS
Properties: dimensionally stable, good strength, impact and toughness
properties, good resistance to abrasion and chemicals
Applications: automotive components, helmets, tool handles, appliances,
boat hulls, luggage, decorative panels
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 Popular Plastics
Polycarbonates
Properties: very versatile and has dimensional stability, good
mechanical and electrical properties, high resistance to impact and
chemicals
Applications: optical lenses, food processing equipments, electrical
components and insulators, medical equipments, windshields, signs,
machine components

Nylons
Properties: good mechanical and abrasion resistance property, self-
lubricating, resistant to most chemicals but it absorbs water, increase in
dimension is undesirable

Applications: mechanical components; gears, bearings, rollers, bushings,

fasteners, guides, zippers, surgical equipments,

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 Applications of Thermosetting Plastics

Epoxies
Properties: good dimensional stability, excellent mechanical and
electrical properties, good resistance to heat and chemicals

Applications: electrical components requiring strength, tools and dies, fiber

reinforced epoxies are used in structural components, tanks, pressure
vessels, rocket motor casing

Phenolics
Properties: good dimensional stability, rigid, high resistance to
heat, water, electricity, and chemicals

Applications: laminated panels, handles, knobs, electrical components;

connectors, insulators

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 Applications of Thermosetting Plastics

Polyesters (thermosetting, reinforced with glass fibers)

Properties: good mechanical, electrical, and chemical properties,
good resistance to heat and chemicals

Applications: boats, luggage, swimming pools, automotive bodies, chairs

Silicones
Properties: excellent electrical properties over a wide rang of
temperature and humidity, good heat and chemical properties

Applications: electrical components requiring strength at high temp.,

waterproof materials, heat seals

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 Website: www.ge.com/plastics
Plastics

Stress vs. Strain

curve

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 Structural and mechanical Appl. Light duty mechanical & decorative
Gears, cams, pistons, rollers, fan Handles, knobs, steering wheel,
blades, rotors, pump impellers, tool handles, pipe fittings, camera
washing machine agitators cases, eyeglass frames
ABS X
Acetal (Delrin) X
Acrylic X
Cellulosics X
Fluoroplastics
Nylon X
Thermoplastics

Phenylene Oxide
Polycarbonate
Polyester
Polyethylene X
Polyimide
Polyenylene sulfide
Polypropylene X
Polystyrene X
Polysulfone X
Polyurethane
Polyvinyl chloride X
Thermosets

Phenolic X X
Polyester
Polyurethane
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 Parts for wear applications Optical and transparent parts
Gears, bearings, bushings, Lenses, safety glasses,
tracks, wheels, ware strips signs, refrigerator shelves,
windshields
ABS
Acetal (Delrin) X
Acrylic X
Cellulosics X
Fluoroplastics X
Nylon X
Thermoplastics

Phenylene Oxide
Polycarbonate X
Polyester
Polyethylene X
Polyimide X
Polyenylene sulfide X
Polypropylene
Polystyrene
Polysulfone X
Polyurethane X X
Polyvinyl chloride
Thermosets

Phenolic
Polyester X
Polyurethane X
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 Small housing & hollow shapes Large housing & hollow shapes
Phone and flashlight cases, Boat hulls, large appliance
helmets, housings for power housings, tanks, tubs,
tools, pumps, small appliances ducts, refrigerator liners
ABS X X
Acetal (Delrin)
Acrylic
Cellulosics X
Fluoroplastics
Nylon
Thermoplastics

Phenylene Oxide X X
Polycarbonate X
Polyester X X
Polyethylene X X
Polyimide
Polyenylene sulfide
Polypropylene
Polystyrene X X
Polysulfone X X
Polyurethane
Polyvinyl chloride X
Thermosets

Phenolic X
Polyester X X
Polyurethane X
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 Structural & Light Small Large Parts for Optical and
Plastic Mechanical duty housing & housing wear transparent
mech & hollow & hollow applications parts
deco shapes shapes
ABS X X X
Acetal (Delrin) X X
Acrylic X X
Cellulosics X X X
Fluoroplastics X
Nylon X X
Thermoplastics

Phenylene Oxide X X
Polycarbonate X X
Polyester X X
Polyethylene X X X X
Polyimide X
Polyenylene sulfide X
Polypropylene X
Polystyrene X X X
Polysulfone X X X X
Polyurethane X X
Polyvinyl chloride X X
Thermosets

Phenolic X X X
Polyester X X X
Polyurethane X X
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 Manufacturing Processes for Plastics

Fabrication of Plastics
Injection Molding

Ejector pin Molded part

Heaters Granular
plastic

Plunger
Torpedo

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 DFM Design Guidelines
Injection Molding
Provide adequate draft
angle for easier mold
removal.

Minimize section thickness,

cooling time is proportional to
the square of the thickness,
reduce cost by reducing the
cooling time.
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 DFM Design Guidelines
Injection Molding

Keep rib thickness less than

60% of the part thickness in
order to prevent voids and
sinks.
Avoid sharp corners, they
produce high stress and
obstruct material flow.

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 DFM Design Guidelines
Injection Molding

Provide smooth transition, Keep section thickness uniform

avoid changes in thickness around bosses.
when possible.

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 DFM Design Guidelines
Injection Molding
• Use standard general tolerances, do not tolerance;
Dimension Tolerance Dimension Tolerance
0 ≤ d ≤ 25 ± 0.5 mm 0 ≤ d ≤ 1.0 ± 0.02 inch
25 ≤ d ≤ 125 ± 0.8 mm 1 ≤ d ≤ 5.0 ± 0.03 inch
125 ≤ d ≤ 300 ± 1.0 mm 5 ≤ d ≤ 12.0 ± 0.04 inch
300 ± 1.5 mm 12.0 ± 0.05 inch
• Minimum thickness recommended;
.025 inch or .65 mm, up to .125 for large
parts.
• Round interior and exterior corners to . Standard thickness
01-.015 in radius (min.), prevents an variation.
edge from chipping.
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 Rotational Molding

Rotational molding process consists of six steps

• A predetermined amount of plastic, powder or liquid
form, is deposited in one half of a mold.
• The mold is closed.
• The mold is rotated biaxially inside an oven.
• The plastics melts and forms a coating over the
inside surface of the mold.
• The mold is removed from the oven and cooled.
• The part is removed from the mold.

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 Rotational Molding Machines

Vertical wheel machine

Turret machine

Shuttle machine
Rock and roll machine
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 Rotational Molding
Advantages
• Molds are relatively inexpensive.
• Rotational molding machines are much less
expensive than other type of plastic processing
equipment.
• Different parts can be molded at the same time.
• Very large hollow parts can be made.
• Parts are stress free.
• Very little scrap is produced

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 Rotational Molding
Limitations

• Can not make parts with tight tolerance.

• Large flat surfaces are difficult to achieve.
• Molding cycles are long (10-20 min.)

Materials
Polyethylene (most common), Polycarbonate (high heat
resistance and good impact strength), Nylon (good wear
and abrasion resistance, good chemical resistance, good
toughness and stiffness).

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 Rotational Molding
Nominal wall thickness
• Polycarbonate wall thickness is typically between .06 to .
375 inches, .125 inch being an ideal thickness.
• Polyethylene wall thickness is in the range of .125 to .25
inch, up to 1 inch thick wall is possible.
• Nylon wall thickness is in the range of .06 to .75 inch.

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 Rotational Molding Examples

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 Rotational Molding Examples

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 Blow Molding
Blow molding is generally the same process as glass blowing
adapted to polymers.
In extrusion blow molding a tube is extruded and clamped in a
split mold. Air under pressure (50-100 psi) is injected into the
tube blowing the plastic outward to fill the mold cavity.

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 Blow Molding
• Blow molding is used for medium size, hollow thin-walled
shapes; containers, tool cases, hollow structures, ….
• Blow molding is limited to thermoplastics such as
polyethylene, polycarbonate, ABS.
• Wall thickness between .015 - .125
• Maximum tolerance .01 - .04

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