Tuesday, 18 November 2025

Evaluating High-Temperature Performance: DMA Comparison of PARA-GF50 vs. PPA(4T)-GF50

Hello and welcome to a new blog post in which we evaluate the high-temperature performance of PARA (PA-MXD6) vs PPA.

When selecting materials for demanding, high-temperature applications, understanding their mechanical performance under heat is critical. Dynamic Mechanical Analysis (DMA) is a powerful tool for assessing how polymers retain their stiffness as temperatures rise. In this post, we compare the high-temperature behavior of two advanced engineering plastics: PA-MXD6-GF50 (50 wt% glass fiber reinforced Polyarylamide) and PPA(4T)-GF50 (50 wt% glass fiber reinforced Polyphthalamide). Both material fall into the category of semi-aromatic polyamides which reflect a resistance towards higher temperatures. In this post we check if this is the case for the both materials. 

DMA Results: Shear Modulus vs. Temperature

Figure 1 presents the dynamic shear modulus (E') of both materials as a function of temperature. The glass transition temperature (Tg) is a key indicator of when a polymer’s mechanical properties begin to decline:

  • PA-MXD6-GF50 (PARA): E' drops sharply at around 85°C, marking its Tg.
  • PPA(4T)-GF50: E' remains stable until approximately 125°C, indicating a higher Tg.

Beyond the glass transition, the differences become even more pronounced. Between 150°C and 200°C, PARA exhibits a slight plateau in modulus before dropping to zero at 250°C. In contrast, PPA(4T)-GF50 maintains a high modulus, retaining around 5 GPa even at 250°C. This demonstrates PPA’s superior ability to withstand elevated temperatures without significant loss of stiffness.

Figure 1: Comparison Dynamic Shear Moldulus E' of PARA-GF50 and PPA(4T).

Thermal Endurance: UL 746B RTI (Strength) Comparison

To further validate these findings, we examined the Relative Thermal Index (RTI, strength at 1.5 mm thickness) according to UL 746B:

  • PA-MXD6-GF50: RTI (strength) = 105°C
  • PPA(4T)-GF50: RTI (strength) = 130°C

The higher RTI value for PPA(4T)-GF50 confirms its suitability for applications requiring long-term mechanical integrity at elevated temperatures.

Ways to increase the thermal performance of PARA / MXD6

Increasing the thermal resistance of PARA/MXD6 can be done by blending PARA with PPE  (Polyphenylenether) and make a MXD6/PPE alloy which not only exhibits high temperature resistance, high strength, but also good and wear resistance.

Conclusion: Material Selection for High-Temperature Applications

DMA provides valuable insight into how materials behave under dynamic loading across a temperature range. For applications operating above 120°C, PPA(4T)-GF50 clearly outperforms PA-MXD6-GF50, maintaining higher modulus and demonstrating better thermal endurance. Alongside DMA, considering the RTI value is essential for making informed material choices in high-temperature environments.

In summary:

  • PPA(4T)-GF50 offers superior high-temperature performance and stability.
  • PA-MXD6-GF50 is suitable for applications up to its Tg and shows property loss at higher temperatures above 200°C.

Selecting the optimal material ensures reliability and safety in demanding thermal conditions. 

Nevertheless, PARA is outperforming PA and PPA in terms of stiffness, combined with excellent surface aesthetics and lowest water uptake allowing for high dimensional stable parts. 

More on PA-MXD6 / PARA here: 

Design Properties for Engineers: The ABCs of Polyarylamide (PARA; MXD6)

Polyarylamide vs Polyamide (PARA vs PA): What are the Major Differences Between PARA and PA (Polymer Material Selection Tip)?

Design Properties for Engineers: The ABCs of Polyarylamide (PARA; MXD6)

PA6.6 vs. PARA - Reducing the Wall Thickness of Injection Moulded Parts (Geometry Optimization Example)

Design Data for PolyArylAmide (PARA; PA MXD6) Selection: Mechanical Properties as Function of Temperature and Humidity

Mastering Injection Molding Tools for High Performance PolyArylAmide (PARA; PA MXD6): 6 Key Steps to Success

Design Properties for Engineers: Superior Gas Barrier Properties of PolyArylAmide (PARA; MXD6)

Check out my Micro Training below too:


And my dedicated Polyarylamide Hub here.

Thanks for reading & #findoutaboutplastics

Greetings,

Herwig Juster

Literature:

[1] https://www.syensqo.com/en/brands/ixef-para

[2] https://plasticsfinder.envalior.com/en/datasheet/ForTii%C2%AE+Ace+MX53/O4A8W

[3] https://www.nexeoplastics.com/types/plastics-database-datasheet?id=2131&product=Ixef%C2%AE&grade=1022

[4] https://www.orinkoplastic.com/PA-6I-6T-And-MXD6-pl60644367.html


Thursday, 13 November 2025

Plastic Part Failure Analysis - Example Breaking of Toy Helicopter Rotor Blades

Hello and welcome to new post in which we discuss one of my plastic part failure studies answering the question: Why did the toy helicopter rotor blades keep breaking?

Ever had a toy fail at the worst possible moment? That’s what happened with a rescue helicopter toy—kids reported the rotor blades snapping during “harder” rescue missions, always at the same spot. As someone who knows the pain of ordering spare parts, I had to dig deeper!

Here’s what I found:

Root Cause: The blades, made from ABS, consistently broke at the injection point—a natural weak spot. When force was applied (think: enthusiastic play!), stress concentrated here, causing failure.

Why Always the Same Spot? The injection point acts like a weak link in a fixed beam. Too much stress, and snap—it breaks right there (Figure 1).

Figure 1: Broken toy helicopter blade - injection molding point as root cause identified. 

How to Fix It?

1. Move the Injection Point: Shift it to the blade’s center using a conical gate, ensuring even filling and less stress (Figure 2).

Figure 2: Moving the injection point to the center allowing for even filling of both blade sides. 

2. Upgrade the Material: Switch to glass fiber reinforced ABS, increasing the needed force to break the rotor blade by 43% (Figure 3)!

Figure 3: Changing from ABS to ABS+GF10 increases the needed force to break the blade. 

3. Combine Both Approaches: For maximum durability.

This is a great reminder: optimal injection molded parts require attention to all five points of the Polymer Product Pentagram—Part Design, Material Selection, Mold Design, Machine Selection, and Molding Process.

Have you faced similar failures? Let’s connect here and share solutions! 

Thanks for reading & #findoutaboutplastics

Greetings,

Herwig Juster

Tuesday, 11 November 2025

Polycarbonate Market Review 2025: Innovation, Growth, and Global Shifts

Hello and welcome to my Polycarbonate Market Review 2025, discussing innovation, growth, and global shifts

Polycarbonate (PC) remains a cornerstone material for modern industry, prized for high impact resistance, optical clarity, and versatility. From automotive and medical to digital electronics and construction, PC and its blends continue to enable the megatrends that define our time.

Why this matters: As global supply chains reset and sustainability moves center stage, the PC market is undergoing meaningful change. In 2024, global PC (including blends) surpassed 5.2 million tons for the first time, and a steady ~4% CAGR is expected— with China and India likely to outpace the global average.


A Material Built for Modern Demands

Pure Polycarbonate offers a rare combination of toughness, transparency, and heat resistance. Its versatility accelerates further through PC blends such as PC+ABS, PC+ASA, PC+PBT, and PC+PET, delivering improved impact performance, heat resistance, stiffness, and chemical durability.

Across digitalization, new mobility, and medical technology, PC and PC blends provide the reliability, design freedom, and performance required for next-generation products.

Market Overview: Recovery Amid Headwinds

Despite structural strengths, producers faced lower demand in recent years and intense competition that pressured prices and margins. European manufacturers contended with higher electricity and gas costs, further tightening profitability.

Even so, momentum is building. The market crossed the 5 million ton threshold in 2024 (5.2 Mt), and forward growth near 4% annually is expected— with faster expansion in China and India.

Global Leaders and Capacity

Two companies account for 40%+ of global PC capacity:

  • Covestro
  • Saudi Basic Industries Corporation (SABIC)

New Chinese entrants—Wanhua Chemical and Zhejiang Petroleum & Chemical (ZPC)—are scaling rapidly, while established players such as Mitsubishi Chemical and Lotte Chemical remain influential.

Capacity and Consumption Snapshot (2024)

  • Production capacity: Asia-Pacific 70% (5.5 Mt; China 3.5 Mt), EMEA 20% (1.4 Mt), Americas 10% (0.8 Mt).
  • End-market usage: Asia-Pacific (incl. China) 70%, EMEA 17%, North & South America 13%. China is the largest single market.

China: The Powerhouse of Growth

China increased PC polymerization plants from 5 (2015) to 17, with exports rising from 250,000 t/y to 500,000 t/y. Notable capacity additions:

  • Hainan Huasheng – 260 kt/y (2022)
  • Sinopec SABIC Tianjin Petrochemical (SSTPC) – 260 kt/y (2022)
  • Hengli Petrochemical – 260 kt/y (2024)
  • Zhangzhou Chimei Chemical – 180 kt/y (2024)
  • Pingmei Shenma – 100 kt/y, with plans to expand to 400 kt/y

Europe: Capacity Contraction and Import Reliance

Trinseo ceased PC production in Stade, Germany; SABIC closed two lines in Cartagena, Spain by end-2023 (now ~130 kt/y). Since 2023, Europe has been the largest net importer of PC, highlighting competitiveness and energy-cost challenges.

The Americas and India: Stability and Ascent

In the U.S., PC production remains stable: SABIC (Indiana, Alabama), Covestro (Texas), and Trinseo (PC compounding). India grew from 125 kt/y (2015) to 300 kt/y. A key milestone: Deepak Chem Tech (DCTL) added 165 kt/y of capacity using Trinseo technology and repurposed equipment from the closed Stade plant—an example of efficient global tech transfer.

Where Polycarbonate Shines: End-Use Segments (2024)

  • Electrical & Electronics (E&E): 35%
  • Automotive: 20%
  • Construction: 15%
  • Consumer goods: 10%
  • Medical, optics, sports, toys, packaging: 20%

Recycling and the Road to Circularity

Three primary routes are advancing PC circularity:

  • Mechanical recycling – efficient for clean, post-industrial streams.
  • Chemical recycling – restoring virgin-like quality; active programs at Covestro, LG Chem, Mitsubishi Chemical, and Wanhua Chemical.
  • Solvent-based recycling – selectively extracts PC from mixed waste; Trinseo’s Terneuzen (NL) pilot, 2023, demonstrates promising results.
Key Data of the Polycarbonate Market Review [1]

Outlook: Resilient and Essential

Despite margin pressure and regional disparities, Polycarbonate remains strategic to innovation in mobility, electronics, healthcare, and sustainable infrastructure. With ongoing capacity investments, stronger Asian supply, and accelerating recycling technologies, the PC market is positioned for steady growth and meaningful transformation in 2025 and beyond.

Thanks for reading & #findoutaboutplastics

Greetings,

Herwig Juster

Friday, 7 November 2025

Wombat: Not Just an Animal—A Lesson for Plastics Operations

Hello and welcome to a new blogpost. When you hear “wombat,” you might picture a sturdy little marsupial from Australia. But in the world of plastics engineering, Wombat stands for something else entirely: 

Waste of Money, Bandwidth, and Time. 

And it’s a concept every polymer professional should keep top of mind.

Wombat in the world of plastics engineering.


Why Wombat Matters in Plastics

In our fast-paced industry, it’s easy to get sidetracked by shiny new technologies, endless data, or meetings that lead nowhere. But every minute and euro spent on non-essential activities is a minute and euro not spent on what really matters: making perfect plastic parts.

Wombat is a reminder to ask ourselves:

  • Are we investing in tools and processes that actually improve quality and efficiency?
  • Is this meeting, report, or project moving us closer to our production goals?
  • Are we focusing on root causes, or just treating symptoms?

Applying Wombat Thinking to the Plastics World

Let’s look at a few practical examples:

  • Material Selection: Don’t over-specify or under-specify. Choose the right polymer for the job, not the most expensive or the one with the flashiest datasheet.
  • Process Optimization: Focus on parameters that truly impact part quality—like melt temperature, cooling time, and pressure—rather than chasing every minor variable.
  • Troubleshooting: When defects arise, use data-driven root cause analysis. Don’t waste time on guesswork or “just try it” fixes.

The Payoff: Perfect Parts, Less Waste

By keeping Wombat in mind, you’ll streamline your operations, reduce scrap, and deliver higher-quality parts—without burning through resources. It’s about working smarter, not harder.

So next time you’re faced with a decision, ask yourself: Is this a Wombat? If it is, steer clear and refocus on what truly drives success in plastics manufacturing.

Let’s leave the wombats in the wild—and keep our operations lean, focused, and efficient!

Thanks for reading & #findoutaboutplastics

Greetings,

Herwig Juster



Monday, 3 November 2025

Ratio Projects - A Story Beyond Plastic Material Prices

Hello and welcome to a new blog post in which I want to share a story that changed the way of thinking about cost-saving in manufacturing:

Ratio projects

Not long ago, I was sitting across the table from a customer who was laser-focused on one thing: lowering material costs for an injection-moulded part. He was convinced that if we could just supply a cheaper material, his problems would be solved.

But as our technical team and I examined the part and the moulding operations together, something caught our eye. The runner and sprue—the channels that guide the molten polymer into the mould—were enormous. In fact, they were much bigger than the part itself! Imagine pouring a glass of water and spilling twice as much on the table as you actually get in the glass. That’s what was happening here.

Instead of just talking about material prices, we rolled up our sleeves and worked side by side with the customer. We reimagined the entire gating system, redesigning the part and the tooling. It was a true collaboration, blending expertise and creativity.

The result? We didn’t just shave a few cents off the material cost. We cut the total cost by 50%. Half! Not by using a cheaper material, but by using our knowledge to optimize the design and the process (Figure 1).

Figure 1: Optimizing the sprue and gating of an injection mold as part of a ratio project.

The customer was amazed. He realized that the real savings came not from squeezing suppliers for lower prices, but from looking at the bigger picture—design, tooling, and production.

This experience taught us all a powerful lesson: sometimes, the answer isn’t in the price tag of the material, but in the ingenuity we bring to the table. When we focus only on material costs, we risk missing out on much greater opportunities for improvement.

So next time you’re tempted to chase the lowest material price, remember—true value comes from partnership, innovation, and seeing the whole picture.

Thanks for reading & #findoutaboutplastics

Greetings,

Herwig Juster


Wednesday, 22 October 2025

Stories From The Granulatefather: The Triangle Test

Stories from the Granulatefather: The Triangle Test by Herwig Juster

The hum of machines filled the air as Anna, a young design engineer, walked briskly through the plastics manufacturing plant. She clutched a sample part in her hand—a translucent connector for a medical device. It looked perfect, but Anna’s brow was furrowed. She had just received a report: several connectors had cracked during field use.

At the conference table, Anna met with her mentor, Mr. DeWitt, a seasoned materials expert. He examined the cracked part, turning it over in his hands. “Environmental stress cracking,” he murmured, almost to himself.

Anna sighed. “I thought we picked the right material. We even checked the chemical compatibility.”

Mr. DeWitt smiled gently. “Let me tell you a rule of thumb I learned early in my career. When it comes to environmental stress cracking—ESCR—think of a triangle. Three legs: environment, stress, and chemicals. If you can remove or reduce even one, you break the triangle and prevent failure.”

Anna leaned in, intrigued. “So, where do we start?”

They walked to the design lab. Mr. DeWitt pointed to the sharp corners on Anna’s part. “Stress concentrates here. Let’s round these edges and thicken the walls. That’ll help.”

Next, they reviewed the cleaning agents used in the hospital. “Some chemicals are harsher than we realized,” Anna noted. “We can recommend alternatives.”

Finally, Mr. DeWitt pulled a datasheet for PPSU, a high-performance polymer. “This material has excellent resistance to ESCR. It might cost more, but it could save us from future failures.”

A week later, Anna watched as the new connectors passed every test—no cracks, no failures. She smiled, remembering the triangle. By tweaking the design, rethinking the chemicals, and upgrading the material, they had broken the cycle of failure.

Anna’s story spread through the company, a reminder that in plastics, success isn’t just about picking a material—it’s about understanding the whole system, and knowing which leg of the triangle to break.

I hope you enjoyed the story!

Thanks for reading & #findoutaboutplastics

Greetings,

Herwig Juster


Tuesday, 21 October 2025

Don't Mix Maximum With Optimum Plastic Material Selection & Plastic Processing I Rule of Thumb

Hello and welcome to a new Rule of Thumb post discussing why mixing maximum with optimum in polymer material selection and plastics processing is not the best thing to do. 

Understanding “Maximum” vs. “Optimum” in Plastic Material Selection

When selecting materials, it’s important to distinguish between “maximum” and “optimum.”

Maximum refers to the highest possible value of a single property (e.g., the highest tensile strength, the greatest heat resistance, or the lowest density).

Optimum means the best possible balance among several relevant properties for a specific application. The optimum is not always the maximum of any single property, but rather the material that meets all key requirements most effectively.

Why is this distinction important?

Choosing a material based solely on a maximum value (such as the strongest or most heat-resistant polymer) can lead to unnecessary costs, processing difficulties, or other trade-offs. The optimal choice is the one that delivers the best overall performance for your specific needs—even if it doesn’t have the highest value in every category.

Example: “Optimal vs Maximum” in Plastic Material Selection

When selecting a plastic material for a specific application, engineers often seek the “optimal vs maximum”—that is, the best possible balance between competing requirements, such as mechanical strength, cost, processability, and chemical resistance.

Case Study: Gear Wheel for Automotive Application

Requirements:

  • High mechanical strength and stiffness
  • Good wear resistance
  • Dimensional stability at elevated temperatures
  • Cost-effectiveness for mass production

Material Candidates:

  • Polyamide 6 (PA6)
  • Polyoxymethylene (POM)
  • Polyetheretherketone (PEEK)

Selection Process:

  1. Define Key Properties:
    The gear must withstand high loads (tensile strength), resist wear, and maintain shape at temperatures up to 120°C.

  2. Score Materials:
    Each candidate is evaluated for tensile strength, wear resistance, heat deflection temperature, and cost.

Find the “Optimal vs Maximum”:

  • PA6: Good strength and cost, but absorbs moisture (affecting dimensions).
  • POM: Excellent wear resistance and dimensional stability, moderate strength, good cost.
  • PEEK: Outstanding properties, but very high cost.

After scoring, POM emerges as the “optimal vs maximum”—it offers the best compromise between performance and cost for this application, even though PEEK has higher absolute properties.

The “optimal vs maximum” is not always the material with the highest individual property, but the one that best meets all critical requirements for the application. In this case, POM is the optimal choice, delivering reliable performance at a reasonable cost.

Takeaway:
When selecting plastics, always look for the “optimal vs maximum”—the material that provides the best overall fit for your application, not just the highest value in a single property.

Optimum vs Maximum in injection molding

For example, in injection molding, the optimum flow rate is not necessarily the fastest possible, but rather the rate that minimizes shear stress, ensures proper mold filling, and avoids defects like air traps or weld lines. Similarly, the optimum temperature profile for a molding process might balance melt temperature for flow with cooling time for cycle time, while minimizing residual stress. 

Figure 1 presents the concept of "maximum vs optimum" for plastics processing. In essence, while maximum settings define the boundaries, optimum settings represent the sweet spot within those boundaries for achieving the best possible results in plastics processing.

Figure 1: Difference between optimum and maximum in plastics processing. 

More Rule of Thumb posts can be found here.

Thanks for reading & #findoutaboutplastics

Greetings,

Herwig Juster

Literature: 

[1] https://youtube.com/shorts/q_KfChgTwdM



Thursday, 16 October 2025

My Highlights from K Fair 2025 – The Global Hub for Plastics & Rubber Innovation

Hello and welcome to a new post! The K trade fair in DΓΌsseldorf once again proved itself as the ultimate meeting place for the plastics world—international, innovative, and truly immense. This year, I had the opportunity to witness some  developments that are shaping the future of our industry, particularly in the areas of sustainability, digitalization, and advanced materials.

K Fair 2025: My highlights and discoveries

My Key Discoveries:

πŸ”Ή China’s Growing Leadership:

Chinese plastics and rubber companies are not only increasing in number—up nearly 50% from the last event, now making China the second-largest exhibiting nation after Germany—but are also leading in innovation, product development, and circular economy initiatives. Their presence and technological advancements were truly impressive.

πŸ”Ή AI in Daily Production:

Artificial intelligence is no longer a buzzword; it’s now an integral part of daily operations. Connected machines and real-time data analysis are accelerating both the speed of innovation and speed to value across the industry.

πŸ”Ή Industry Transformation:

While revenue growth remains a challenge, this period is being used as an opportunity to streamline internal structures and consolidate portfolios, preparing for a more resilient future.

πŸ”Ή Energy Costs & Plant Closures:

High energy costs in Europe continue to impact the sector, leading to the closure of several chemical plants—a trend that cannot be ignored.

πŸ”Ή Recycling as a Sustainability Driver:

Recycling has evolved from a cost-saving measure to a key driver of sustainability, especially when combined with product carbon footprint passports and digital material twins.

πŸ”Ή M&A Activity:

Mergers and acquisitions remain active, with notable deals such as Engel’s acquisition of Trexel, a specialist in foaming technology for injection molding.

Let us deeper dive into the latest innovations in circular economy and recycling, digitalization and smart manufacturing, new materials, and machinery enhancements:

Circular economy and recycling innovations

Next-level recycling technologies: Companies like Gneuss showcased melt filtration and extrusion technologies designed to significantly improve recycling processes. The VDMA's Circular Economy Forum provided live demonstrations of implementing circularity within plastics production.

High-quality recycled materials: BioPlastics & Recycling GmbH presented certified post-consumer recycled (PCR) regranulates, including rPP and rPE with FDA approval, setting new standards for quality and sustainability.

Upcycled materials: Researchers showcased new materials, such as the BAETA technology, which transforms recycled PET bottles into carbon capture material.

Sustainable product design: Prototypes and commercial products were presented that were designed for better recyclability, including mono-material solutions and reusable systems. For example, Covestro and VAUDE introduced a recyclable, mono-material backpack made from TPU. 

Innovative recycling technology: Syensqo showcased its innovative recycling technology for circular sulfone polymers. 

Digitalization and smart manufacturing

Artificial intelligence (AI), the Internet of Things (IoT), and automation were on display to showcase the future of smart manufacturing. 

AI for efficiency and sustainability: Exhibitors highlighted how AI-based process optimization can increase the throughput of blown film lines, automatically coordinating components for greater efficiency. ReifenhΓ€user also introduced "ReifenhΓ€user Next," a brand centered on an AI chatbot and digital learning platforms to combat skilled labor shortages and solve production challenges.

Digital twins: This technology was featured for creating virtual representations of production lines, allowing for the simulation and optimization of manufacturing processes before physical implementation.

Predictive maintenance: Advanced sensor technology and cloud applications enable the real-time monitoring of machinery, allowing for predictive maintenance that reduces unplanned downtime.

Digital Product Passports (DPP): In response to EU regulations, new technologies were presented to support the implementation of Digital Product Passports, which provide information on a product's raw materials, production processes, and recycling paths. 

New and advanced materials

Sustainable polycarbonates: Covestro showcased its Makrolon® RE and Makrolon® RP polycarbonates, which incorporate recycled content or are based on renewable raw materials. These were used in applications ranging from electronics to medical devices.

Bio-based alternatives: The Fraunhofer Institute presented a new helmet made from bio-based polylactide (PLA), offering comparable protection to conventional helmets with a two-thirds reduction in CO2 emissions. Expanded PLA (EPLA) was also shown as a sustainable alternative to EPS foam.

High-performance materials for e-mobility: Complex busbars: Syensqo collaborated with Clayens to present a 360-degree approach for developing complex busbars for electric vehicles. 

Recycled polyamide: RadiciGroup received an award for a battery module made from its recycled Renycle polyamide. 

New polymer distribution companies: Omya's polymer distribution business made its official debut as the newly formed Omya Performance Polymer Distribution at the K Fair 2025 in DΓΌsseldorf. The company showcased its portfolio of specialty polymers, innovations, and solutions for the plastics industry.  

Machinery and equipment enhancements

Manufacturers introduced new and improved machinery that was faster, more efficient, and better integrated with digital systems. 

First all-electric, tie-bar-less injection molding machine: ENGEL unveiled the new victory electric, its first all-electric, tie-bar-less injection molding machine, which combines their electric drive technology with their tie-bar-less design for increased efficiency and precision. The new machine is a world premiere that focuses on design advancements to meet specific customer requirements for greater benefits.  

Smaller, faster machines: KraussMaffei introduced a process that compounds glass fiber rovings directly in the injection molding unit to reduce material costs. Netstal showcased its new-generation Elion MED series for medical technology, known for its speed and precision.

Simplified tool changeovers: Guill Tool & Engineering introduced its Cam-Lock system, designed to simplify tool changeovers on its extrusion heads.

Upgraded extrusion lines: BrΓΌckner presented its Greenline concept for film stretching lines, a new system for high-performance films, featuring a digital standard interface. 

And of course, one of the true highlights: reconnecting with old friends and colleagues from across the plastics industry—the K Fair always feels like a family reunion!

Thanks for reading & #findoutaboutplastics

Greetings,

Herwig Juster

Literature: 

[1] https://en.kunststoffe.de/k-fair#:~:text=Increase%20in%20Exhibitors%20at%20K,Fast%2C%20Precise%20and%20Reliable

[2] https://solutions.covestro.com/en/digital-event-space/kfair

[3] https://www.specialchem.com/plastics/news/syensqo-to-showcase-high-performance-polymers-portfolio-at-k-2025#:~:text=Syensqo%20will%20make%20its%20first,15th%20in%20D%C3%BCsseldorf%2C%20Germany.

[4] https://www.plastech.biz/en/news/Syensqo-to-debut-at-K-2025-with-specialty-polymers-portfolio-21142#:~:text=Partnerships%20and%20live%20program%20at,for%20single%2Duse%20surgical%20instruments

[5] https://www.k-online.com/#:~:text=K%202025%20focuses%20on%20key,be%20returned%20directly%20on%20site.

[6] https://www.omya.com/en/industries/polymers/events/omya-at-k-show-2025#:~:text=Recently%20founded%20Omya%20Performance%20Polymers,the%20regional%20leadership%20team%20(bios)

Wednesday, 1 October 2025

Say Goodbye to PTFE? Discover the UHMW-PE Advantage in Plastics

Hello and welcome to a new post in which we are looking for a smarter way to reduce friction and wear in engineering plastics—without relying on PTFE.

Replacement of PTFE with UHMW-PE - How much should I add?

Ultra-High-Molecular-Wheigt-Polyethelyne (UHMW-PE) stands out as a highly effective alternative to PTFE and molybdenum disulfide, especially when high temperatures are not a concern for your final application. Discover how this innovative approach can boost performance and open new possibilities for your polymer selection and engineering plastics projects.

Table 1 shows how adding just 5 wt% of UHMW-PE to materials like PA 6 can dramatically lower the kinetic friction coefficient from 0.6 to 0.23. Similar improvements are possible with PBT (from 0.51 to 0.2) and PPS (from 0.38 to 0.14)!


Check out this post too πŸ‘‰Polymer Material Selection: What are PTFE free alternatives for friction and wear compounds?

Thanks for reading & #findoutaboutplastics

Greetings,

Herwig Juster

Literature: 

[1] https://plasticker.de/news/shownews.php?nr=45528&nlid=64581.d.h.2024-10-30

[2] https://www.findoutaboutplastics.com/2022/07/polymer-material-selection-what-are.html

Wednesday, 17 September 2025

Designers & Engineers: Tired of Warped Polyamide Parts? Meet PolyArylAmide (PA MXD6)!

Hallo and welcome to a new blog post on one of my favorite high performance Polyamides: PA-MXD6 (also known as Nylon MXD6, or simple PARA). 

When designing with glass fiber-reinforced polymers, warpage is a common challenge—especially as fiber content increases. But what if you could achieve both high strength and dimensional stability?

Warpage Comparison: PA 6.6-GF30 vs PA MXD6-GF50

Figure 1 compares the warpage behaviour of a plate moulded in PA 6.6-GF30 and PA-MXD6-GF50. The graps shows that: 

πŸ”Ή PA-MXD6-GF50 (50 wt% glass fiber) shows dramatically lower warpage and anisotropy than standard PA 6.6 GF30 (30 wt% GF)—even with a 20 wt% higher glass content!

πŸ”Ή Lower anisotropy means your parts stay true to design, reducing costly rejects and post-processing.

πŸ”ΉPARA’s unique structure minimizes the difference between parallel and transverse shrinkage, delivering precision and reliability for your most demanding applications.

Figure 1: Warpage comparison of PA 6.6-GF30 vs PA MXD6-GF30 and PA MXD6-GF50 [3].

Why compromise? Choose PARA for your next polymer selection project to achieve:

  • Tighter tolerances
  • Superior aesthetics
  • Consistent, high-quality parts

More on PA-MXD6 / PARA here: 

Polyarylamide vs Polyamide (PARA vs PA): What are the Major Differences Between PARA and PA (Polymer Material Selection Tip)?

Design Properties for Engineers: The ABCs of Polyarylamide (PARA; MXD6)

PA6.6 vs. PARA - Reducing the Wall Thickness of Injection Moulded Parts (Geometry Optimization Example)

Design Data for PolyArylAmide (PARA; PA MXD6) Selection: Mechanical Properties as Function of Temperature and Humidity

Mastering Injection Molding Tools for High Performance PolyArylAmide (PARA; PA MXD6): 6 Key Steps to Success

Design Properties for Engineers: Superior Gas Barrier Properties of PolyArylAmide (PARA; MXD6)

Check out my Micro Training below too:


And my dedicated Polyarylamide Hub here.

Thanks for reading & #findoutaboutplastics

Greetings,

Herwig Juster

Literature:

[1] https://www.carbonele.com/news/pa-mxd6-material-properties-and-applications/

[2] https://onlinelibrary.wiley.com/doi/10.1002/app.56089

[3] https://www.syensqo.com/en/chemical-categories/specialty-polymers/technical-literature

[4] www.polyarylamide.com

[5] https://www.researchgate.net/publication/334669698_Effect_of_Fillers_and_Processing_Parameters_on_the_Shrinkage_of_Injected_Molding_Polyamide_66/link/5d39300292851cd04684421d/download?_tp=eyJjb250ZXh0Ijp7ImZpcnN0UGFnZSI6InB1YmxpY2F0aW9uIiwicGFnZSI6InB1YmxpY2F0aW9uIn19

[6] https://www.materialdatacenter.com/ms/de/Reny/Mitsubishi+Engineering-Plastics+Corporation/Reny+1002H/7617eb67/1617

Wednesday, 10 September 2025

Mastering Injection Molding Tools for High Performance PolyArylAmide (PARA; PA MXD6): 6 Key Steps to Success

Hello and welcome to a new blog post. Today we dive into the optimal tool making for Polyarylamide parts. 

Designing and producing injection molding tools for Polyarylamide (PARA; PA-MXD6) is both an art and a science. This high-performance polymer offers outstanding mechanical properties and surface aesthetics—but only if your tooling is up to the challenge! 

Here’s a deep dive into the six essential steps for success (Figure 1):

Figure 1: Overview of the six steps of tool making for molding Polyarylamide (PARA; MXD6). 

1️⃣ Part Design: Build on Solid Foundations

  • Use generous radii (≥0.6 mm) to reduce stress and ease ejection.
  • Apply draft angles: at least 1° for polished, up to 3° for textured surfaces.
  • Optimize gate placement and size—locate at the thickest section, with land lengths of 0.8–1.6 mm.
  • Take advantage of PARA’s low shrinkage (0.20–0.25%) for tight tolerances and minimal sink marks.
  • Simulate your design (Moldflow®, Flow-3D®) to predict flow, weld lines, and optimize geometry.

2️⃣ Mold Definition: Specify for Performance

  • Select abrasion-resistant steel (≥54 HRc) like Stavax ESR or Orvar Supreme to withstand glass fiber wear.
  • Design for “steel safe” dimensions—easier to remove than add steel!
  • Ensure robust venting (max 0.01 mm) and cooling (10 mm channels, 15–20 mm spacing).
  • Use hot runners for efficiency and consistent quality.
  • Calculate clamping force: 1 ton/cm² of projected area.
  • Add cavity pressure sensors for processing optimization, especially with multi-cavity tools.

3️⃣ Detailed Drawings & Production: Precision Matters

  • Prepare comprehensive technical drawings with all tolerances and features.
  • Plan for heat treatment and machining—every detail counts for tool longevity and part quality.

4️⃣ Cutting Steel: Prepare for the Long Haul

  • Mill, heat treat, and quench your steel to achieve optimal hardness.
  • Allow for deformation during heat treatment (“steel safe” approach).
  • After treatment, remove any brittle, oxidized layers by sandblasting to prevent future tool issues.

5️⃣ Assembly & Testing: Fine-Tune for Perfection

  • Assemble and adjust all tool components, ensuring smooth operation.
  • “Blueprint” the tool at low clamping force to check split lines and prevent flash (PARA has good flow properties, similar to PPS).
  • Design for easy maintenance: include features like mold centering adjusters, ejector return pins, and replaceable components.

6️⃣ Polishing & Surface Treatments: Finish Strong

  • Polish all surfaces to ensure easy part ejection and premium aesthetics.
  • Apply specialized surface treatments to extend tool life—especially important with glass-filled PARA.

Pro Tip:
PARA’s high flow and low shrinkage enable thin, complex parts with exceptional surface quality. But to fully leverage these benefits, every step of your tooling process must be meticulously planned and executed.

Are you working with PARA or considering it for your next project? Let’s connect and share best practices for robust, reliable, and beautiful injection-molded parts!

More on PA-MXD6 / PARA here: 

Polyarylamide vs Polyamide (PARA vs PA): What are the Major Differences Between PARA and PA (Polymer Material Selection Tip)?

Design Properties for Engineers: The ABCs of Polyarylamide (PARA; MXD6)

Design Data for PolyArylAmide (PARA; PA MXD6) Selection: Mechanical Properties as Function of Temperature and Humidity

Thanks for reading & #findoutaboutplastics

Greetings,

Herwig Juster

Literature:

[1] Syensqo - Ixef PARA Design Guide

Wednesday, 3 September 2025

Turning Product Requirements into Plastic & Plastic Part Specifications: The Key to Successful Material Selection!

Hello and welcome to a new blog post where we discuss an important material selection topic. 

When developing a plastic part, clear and meaningful specifications are essential—they help control variations in function, appearance, and cost. By translating product requirements into detailed plastic specifications, you set the foundation for selecting the optimal material and ensuring consistent quality. Also, the specifications will help for sourcing plastic parts with the correct material. 

What should a robust plastic specification and plastic part specification include? 

✔️ Material brand, grade, and generic name (e.g., Ryton® R-4-200BL, PPS)

✔️ Surface finish

✔️ Desired parting line location

✔️ Flash limitations

✔️ Permissible gating and weld line areas

✔️ Void intolerance zones

✔️ Allowable warpage

✔️ Tolerances

✔️ Color

✔️ Decorating needs

✔️ Performance criteria

Example of turning a product requirement into a plastic specification:

If your product requirement is “the part must withstand high temperatures, needs to have low tolerance, and have a glossy black finish,” this translates into a plastic specification such as:

  • Material: Ryton® R-4-200BL (PPS) for heat resistance
  • Color: Black, high-gloss surface finish
  • Tolerance: ±0.05 mm
  • No voids allowed in load-bearing areas
  • Gating away from visible surfaces

Figure 1 demonstrates how plastic specifications act as a bridge between product requirements, material selection, and support for sourcing. First we turn product requirements into proper plastic specifications, which we can use for polymer selection. After identifying the plastic grade we can add it with commercial name to our specification list and use it for sourcing or to find alternativ materials, as well as sourcing the plastic parts themselfs. 

Figure 1: Plastic specifications as bridge between product requirements, material selection, and support for sourcing. 

Conclusions

Having proper specifications not only streamlines the material selection phase, but also greatly supports sourcing—especially when you need to identify or qualify alternative materials. Clear specifications ensure you can compare options confidently and maintain quality, even when supply chains change.

Getting these details right means your part will meet all functional, aesthetic, and economic goals. Start with clear specs—finish with a successful product!

Thanks for reading & #findoutaboutplastics

Greetings,

Herwig Juster

Literature:

[1] Herwig Juster - Polymer Material Selection, 2023