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Polymer Processing
Plastics
Blow Molding Plastic is a commercial name for a group of materials that while being processed, can be pushed or formed
into almost any desired shape and then retain that shape. Plastics can be cast, molded, or pressed into an
Injection Molding unlimited variety of shapes. They are one of the most used materials on a volume basis in industrial and
Metal Injection Molding commercial life. Plastics are on par with metals, wood, and ceramics and are essential to the needs of virtually
the entire spectrum of business. Plastics, properly applied, will perform functions at a cost that other materials
Thermoforming cannot match.
Metal Casting
Most plastics can be classified as either thermoplastic or thermosetting materials. Thermoplastic materials
Centrifugal Casting can be formed into desired shapes under heat and pressure and become solids on cooling. If they are
Die Casting subjected to the same conditions of heat and pressure, they can be reprocessed into new shapes.
Thermosetting materials are like concrete, once processed and shaped, they cannot be reshaped. Today, the
Investment Casting vast majority of plastics are thermoplastics.
Permanent Mold
Plastics are made up of polymers. Polymeric materials are characterized by long chains of repeated molecule
Sand Casting units known as "mers". These long chains intertwine to form the bulk of the plastic. The ways in which the
Shell Mold Casting chains intertwine determine the plastic's macroscopic properties. Typically, the polymer chain orientations are
random and give the plastic an amorphous structure. Amorphous plastics have good impact strength and
Machining
toughness. Examples include acrylonitrile-butadiene-styrene (ABS), styrene-acrylonitrile copolymer (SAN),
Milling polyvinyl chloride (PVC), polycarbonate (PC), and polystyrene (PS).
Turning
If instead the polymer chains take an orderly, densely packed arrangement, the plastic is said to be crystalline.
Hole-making Crystalline plastics share many properties with crystals, and typically will have lower elongation and flexibility
Drill Size Chart than amorphous plastics, and better chemical resistance. Examples of crystalline plastics include acetal,
polyamide (PA; nylon), polyethylene (PE), polypropylene (PP), polyester (PET, PBT), and polyphenylene sulfide
Tap Size Chart (PPS). Advances in chemistry have made the distinction between crystalline and amorphous less clear, since
Sheet Metal Fabrication some materials like nylon are formulated both as a crystalline material and as an amorphous material.

Forming
Thermoplastics and Thermosets
Cutting with shear
Cutting without shear
Material name Abbreviation Trade names Description Applications
Gauge Size Chart Strong, rigid,
Additive Fabrication excellent fatigue
Bearings, cams,
resistance, excellent
SLA Celcon, gears, handles,
creep resistance,
Delrin, plumbing
FDM Acetal POM chemical resistance,
Hostaform, components, rollers,
moisture resistance,
SLS Lucel rotors, slide guides,
naturally opaque
valves
DMLS white, low/medium
cost
3D Printing
Display stands,
Inkjet Printing Diakon, Rigid, brittle, scratch
knobs, lenses, light
Oroglas, resistant, transparent,
Jetted Photopolymer Acrylic PMMA housings, panels,
Lucite, optical clarity,
reflectors, signs,
LOM Plexiglas low/medium cost
shelves, trays
Materials Strong, flexible, low
Metals mold shrinkage (tight
Automotive
Cycolac, tolerances), chemical
Plastics (consoles, panels,
Acrylonitrile Magnum, resistance,
ABS trim, vents), boxes,
Case Studies Butadiene Styrene Novodur, electroplating
gauges, housings,
Cost Analysis Terluran capability, naturally
inhalors, toys
opaque, low/medium
Part Redesign cost
Product Development Dexel,
Tough, transparent, Handles, eyeglass
Cellulose Acetate CA Cellidor,
Resources high cost frames
Setilithe
Curriculum Resources
High strength, fatigue
Glossary resistance, chemical
Akulon,
resistance, low creep, Bearings, bushings,
Polyamide 6 (Nylon) PA6 Ultramid,
low friction, almost gears, rollers, wheels
Grilon
opaque/white,
medium/high cost
High strength, fatigue
resistance, chemical
Handles, levers,
Polyamide 6/6 Kopa, Zytel, resistance, low creep,
PA6/6 small housings, zip
(Nylon) Radilon low friction, almost
ties
opaque/white,
medium/high cost
 High strength, fatigue
resistance, chemical Air filters, eyeglass
Polyamide 11+12 Rilsan, resistance, low creep, frames, safety
PA11+12
(Nylon) Grilamid low friction, almost masks
opaque to clear, very
high cost
Automotive (panels,
Very tough, lenses, consoles),
Calibre, temperature bottles, containers,
Polycarbonate PC Lexan, resistance, housings, light
Makrolon dimensional stability, covers, reflectors,
transparent, high cost safety helmets and
shields
Automotive (filters,
handles, pumps),
bearings, cams,
Celanex,
Rigid, heat resistance, electrical
Polyester - Crastin,
PBT, PET chemical resistance, components
Thermoplastic Lupox, Rynite,
medium/high cost (connectors,
Valox
sensors), gears,
housings, rollers,
switches, valves
Tough, very high
Polyether Sulphone PES Victrex, Udel chemical resistance, Valves
clear, very high cost
Strong, thermal
Aircraft components,
stability, chemical
electrical
Polyetheretherketone PEEKEEK resistance, abrasion
connectors, pump
resistance, low
impellers, seals
moisture absorption
Electrical
Heat resistance, components
flame resistance, (connectors, boards,
Polyetherimide PEI Ultem
transparent (amber switches), covers,
color) sheilds, surgical
tools
Lightweight, tough
Alkathene, and flexible, excellent Kitchenware,
Polyethylene - Low
LDPE Escorene, chemical resistance, housings, covers,
Density
Novex natural waxy and containers
appearance, low cost
Tough and stiff,
Eraclene, excellent chemical Chair seats,
Polyethylene - High
HDPE Hostalen, resistance, natural housings, covers,
Density
Stamylan waxy appearance, and containers
low cost
Tough, heat
Automotive
resistance, flame
(housings, panels),
Noryl, resistance,
electrical
Polyphenylene Oxide PPO Thermocomp, dimensional stability,
components,
Vamporan low water absorption,
housings, plumbing
electroplating
components
capability, high cost
Bearings, covers,
Very high strength, fuel system
Polyphenylene
PPS Ryton, Fortron heat resistance, components, guides,
Sulphide
brown, very high cost switches, and
shields
Lightweight, heat
resistance, high Automotive
Novolen, chemical resistance, (bumpers, covers,
Polypropylene PP Appryl, scratch resistance, trim), bottles, caps,
Escorene natural waxy crates, handles,
appearance, tough housings
and stiff, low cost.
Lacqrene,
Polystyrene - General Brittle, transparent, Cosmetics
GPPS Styron,
purpose low cost packaging, pens
Solarene
Impact strength,
Polystyrol, rigidity, toughness,
Polystyrene - High Electronic housings,
HIPS Kostil, dimensional stability,
impact food containers, toys
Polystar naturally translucent,
low cost
Tough, flexible, flame Electrical insulation,
Polyvinyl Chloride - resistance, housewares, medical
PVC Welvic, Varlan
Plasticised transparent or tubing, shoe soles,
opaque, low cost toys
Tough, flexible, flame
Outdoor applications
 Polyvinyl Chloride - UPVC Polycol, resistance, (drains, fittings,
Rigid Trosiplast transparent or gutters)
opaque, low cost
Stiff, brittle, chemical
Luran, resistance, heat
Housewares, knobs,
Styrene Acrylonitrile SAN Arpylene, resistance,
syringes
Starex hydrolytically stable,
transparent, low cost
Hytrel, Bushings, electrical
Thermoplastic Tough, flexible, high
TPE/R Santoprene, components, seals,
Elastomer/Rubber cost
Sarlink washers

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