Design-to-Cost (DTC) in Plastic Part Design - Example housing for electronic device

Hello and welcome to a new post. In today's post we discuss the Design-to-Cost (DTC) approach in plastic part design.

Example housing for electronic device

A company is developing a new plastic housing for an electronic device. The target cost for the housing is €1.00 per unit, including material, manufacturing, and finishing.

Figure 1: 5 steps of a Design-to-cost approach for a plastic part design

Step 1: Set Cost Target

The project team establishes that the plastic housing must not exceed €1.00 per unit to remain competitive in the market.

Step 2: Analyze Cost Drivers

Material selection: Polycarbonate (PC) is initially considered, but its cost is relatively high.

Wall thickness: Thicker walls increase material usage and cycle time.

Part complexity: Complex geometries require more expensive tooling and longer molding cycles.

Surface finish: High-gloss or textured finishes may require additional processing.

Step 3: Generate Design Alternatives

Material: Evaluate switching from PC to a less expensive material, such as polypropylene (PP) or ABS, if performance requirements allow.

Wall thickness: Reduce wall thickness from 2.5 mm to 2.0 mm, maintaining structural integrity through ribbing and optimized geometry.

Geometry: Simplify the design by minimizing undercuts and eliminating unnecessary features, allowing the use of a simpler mold.

Surface finish: Specify a standard mold finish instead of a high-gloss or textured finish to reduce costs.

Step 4: Cost Estimation and Iteration

The team estimates the cost of each design alternative using supplier quotes and manufacturing simulations.

For example, switching to ABS and reducing wall thickness lowers material and cycle time costs, bringing the estimated cost to €0.95 per unit.

Step 5: Finalize Design

The design that meets both functional requirements and the cost target is selected.

The team documents the design choices and cost rationale for future reference.

Conclusions 

By applying the Design-to-Cost method, the team systematically reviewed material, geometry, and process options to ensure the plastic part meets its cost target without compromising essential performance.

Thanks for reading & #findoutaboutplastics!

Greetings, 

Herwig Juster

🔎I review your polymer material selection and plastic part design - contact me here

🔥 There is a problem keeping you awake - My personal website for Polymer Consulting

📊 Discover your Polymer Material Selection score by taking quick test here

Literature: 

[1] https://www.megatron.de/en/category/plastic-housing.html

How many cavities should you choose for your injection molding tool? I Rule of Thumb Polymer Processing

Hello and welcome to a new post. In today's post we discuss a community question I received:

How many cavities should you choose for your injection molding tool?

It’s a question that can make or break your project’s budget. Go too low, and you’re missing out on efficiency. Go too high, and tooling costs skyrocket.

Figure 1 [1] compares the cost of the injection mold, material, and injection molding as function of the mold cavities.  The sweet spot is at eight cavities as the optimal cavity number before costs start to climb. It is a classic "bathtub" cost curve and allows one to balance between tooling investment and production savings. 

Figure 1: Choosing the optimal umbers of mold cavities [1].

Conclusions

This curve serves as a first orientation. Important is that you collect all your costs and create such a total cost curve on your own. It depends if you are molding a packaging part, where more than eight cavities are beneficial, or if you are molding an engineering part such as a connector with pin overmolding, where fewer cavities may lead to an optimum already. 

Update - I received an interesting feedback: Prof. Jozsef Kovacs from University of Budapest highlights that László Sors developed a comprehensive analytical method for cavity number optimization as early as 1966, including equations, practical examples, and a nomogram. Sors’s work also addressed prototype molds, tool cost-efficiency, and the integration of thermal, rheological, and electrical calculations into mold design—well before these became industry standards. Sors is recognized as a pioneering figure in polymer tooling and design, leaving a significant legacy in the field. He published his know-how in the 1966 book: Műanyag-alakító szerszámok.

More "Rules of Thumb" posts can be found under "start here".

Thanks for reading & #findoutaboutplastics!

Greetings, 

Herwig Juster

🔎I review your polymer material selection and plastic part design - contact me here

🔥 There is a problem keeping you awake - My personal website for Polymer Consulting

📊 Discover your Polymer Material Selection score by taking quick test here

Literature: 

[1] A. Pouzada: Design and Manufacturing of Plastics Products: Integrating Traditional Methods With Additive Manufacturing

[2] H. Juster: Optimizing your injection moulding production – my 5+ How’s I Plastics processing tips

Discover the Future of Polyketone Selection: Introducing the Aliphatic Polyketone (PK) Grade Screening App

Hello and welcome to a new blog post in which I introduce to you my new created Polyketone selection app. 

Polymer Material Selection and Plastic Part Design with Polyketone

In the fast-paced world of polymer material selection and plastic part design, finding the right material can be a daunting task. With the growing demand for high-performance, sustainable materials, aliphatic Polyketone (PK) is gaining renewed attention among engineers and designers—especially in Europe. That’s why I’m excited to introduce my newly developed app, designed to revolutionize the way you scout and screen commercial aliphatic Polyketone grades!

A Brief Journey Through Polyketone’s History

Polyketone’s story is as unique as its properties. Originally launched in the 1990s by Shell under the brand name Carilon, aliphatic Polyketone quickly attracted interest for its remarkable balance of mechanical and chemical properties. However, the material was discontinued in 2000, leaving a gap in the market. Fast forward to 2013, and Hyosung Corporation breathed new life into PK with the launch of Poketone, making this versatile polymer available once again.

What makes Polyketone so special? 

Its semi-crystalline molecular structure, alternating between carbon monoxide (CO) and olefin, imparts a unique set of properties. PK is available as both a copolymer (ethylene and CO) and a terpolymer (ethylene, propylene, and CO). The terpolymer variant, in particular, offers enhanced processing for extrusion and injection molding applications. Thanks to its excellent mechanical strength, chemical resistance, and low permeability, PK is a strong candidate to replace traditional engineering polymers like Polyamides, POM, and PBT.

Your New Go-To Tool for PK Grade Selection

Selecting the right Polyketone grade just got easier! My new app (try out here) is tailored to help engineers, designers, and material specialists efficiently navigate the landscape of commercially available aliphatic PK grades—focusing on European providers.

Two Powerful Ways to Search

1. Direct Grade Selection:

Choose from a comprehensive list of commercial Polyketone grades. Instantly access key properties such as:

• Tensile strength
• Tensile modulus
• Elongation at break
• Heat Deflection Temperature (HDT) at 1.8 MPa
• UL rating
• Charpy notched impact

2. Property-Based Search:

Have specific requirements in mind? Simply enter your desired property values, and the app will recommend matching commercial PK grades that fit your needs.

This dual approach streamlines the material selection process, saving you valuable time and ensuring you find the best fit for your application.

Figure 1: Overview of the Polyketone Selector "PK Selector" V1.

Built for the Community—And Growing!

This is just the beginning. As the first version, the app currently covers the most critical properties and a robust selection of grades. Over time, I plan to expand the database with more properties and additional grades, making the tool even more powerful and versatile.

Get Involved!

I invite you to try out the new Polyketone selection tool here and experience a smarter way to choose your next engineering polymer. Your feedback is invaluable—please share your thoughts, suggestions, or feature requests to help shape future updates.

Are you a supplier or manufacturer with a Polyketone grade you’d like to see listed? Reach out to me directly—I’m eager to collaborate and make this resource as comprehensive as possible for the entire community.

Ready to streamline your Polyketone selection process? Try the app today and join the conversation!

Thanks for reading and trying out the app!

Greetings and #findoutaboutplastics

Herwig 

Literature: 

[1] https://www.poketone.com/en/index.do

[2] https://www.polyketon.de/

Choosing the Right Polymer: Why the Cheapest Isn’t Always the Best (Example Rib Plate)

Hello and welcome to a new blog post. When it comes to creating a successful product, the material you choose can make or break your design—literally! Imagine you’re building a plate that needs to be stiff enough to withstand bending (Figure 1). You have a few plastics in mind: unreinforced Polyamide 6.6 (PA 6.6), Polypropylene (PP), and High-Density Polyethylene (HDPE). Which one should you pick? If you’re thinking, “Easy! Just go for the cheapest per kilogram,” think again.

Let’s dive into the fascinating world of material selection, where things aren’t always as simple as they seem.

The Price Tag Trap

At first glance, HDPE looks like a winner. It’s often the least expensive plastic by weight. But here’s the twist: not all plastics are created equal when it comes to stiffness. To achieve the same bending stiffness as PA 6.6 or PP, you’d need to make your HDPE plate much thicker. Why? Because HDPE has a lower modulus of elasticity—it’s just not as stiff.

Figure 1: Example material selection of rib plate - HDPE vs PP vs PA 6.6 [1]. 

The Domino Effect of Thickness

Making the plate thicker doesn’t just mean using more material (and thus, more cost). In injection molding, thicker parts take longer to cool. In fact, the cooling time increases with the square of the wall thickness! That means your production slows down, your output drops, and your costs go up. Suddenly, that “cheap” HDPE isn’t looking so cheap after all.

The Surprising Winner

In our example, the most expensive material per kilogram—Polyamide 6.6—turned out to be the most cost-effective overall. Its higher stiffness meant we could use less material and keep production fast and efficient. Sometimes, paying more upfront saves you money in the long run. Also, you can decrease the wall thickness even more, by using a PolyArylAmide (PARA; MXD6) instead a PA 6.6. 

Beyond the Numbers

Of course, cost isn’t the only factor. When choosing a material, you also need to consider physical, chemical, and thermal properties, as well as how easy it is to process. The “right” material is the one that balances all these needs for your specific application.

The Takeaway

Next time you’re selecting a material, remember: the cheapest option per kilogram might not be the cheapest solution for your product. Think about requirements such as stiffness, processing time, and all the other requirements (chemical resistance) your product needs to meet. A little extra thought at the beginning can save a lot of headaches—and money—down the line.

Let’s Talk About Your Design!

Do you have a plastic part design or a material selection challenge? I’d love to hear about it! Share your project or questions with me here, and I’ll be happy to provide feedback and help you find the best solution for your needs. Let’s make your next product a success—together!

Thanks for reading and #findoutaboutplastics

Greetings, 

Herwig Juster

🔎I review your polymer material selection and plastic part design - contact me here

🔥 There is a problem keeping you awake - My personal website for Polymer Consulting

📊 Discover your Polymer Material Selection score by taking quick test here

Literature:

[1] Konstruieren mit Kunststoffen - IKKV, University Leoben

[2] https://www.findoutaboutplastics.com/2025/04/nature-is-built-on-5-polymers-modern.html

[3] www.polymermaterialselection.com

Plastic Part Failure Analysis - Using Thermal Analysis (DSC) to Estimate the Anti-Oxidant Level in Polymers

Hello and welcome to a new blog post. Let me start today with the following question: How do you ensure the long-term performance of polyolefin materials in demanding applications?

Understanding and measuring oxidative stability is key. The following post explores why oxidative stability matters for polyolefins like polypropylene, and how Differential Scanning Calorimetry (DSC) provides valuable insights into material durability, processing effects, antioxidant performance, and ultimately prevent plastic part failure. Dive in to learn how this classic yet often overlooked test method can help you make informed decisions about material selection and process optimization.

DSC Testing for Oxidative Stability

DSC measures the heat absorbed or released by a material as temperature or time changes. While commonly used for phase transitions (melting, recrystallization, glass transition), it is also effective for detecting exothermic events like oxidation.

How does a typical test procedure for oxidative stability look like?

• A sample (raw material or molded part) is placed in the DSC.
• The sample is heated in a nitrogen atmosphere to a set temperature (commonly 200°C/392°F, which melts PE or PP).
• After reaching the target temperature, air or oxygen is introduced.
• The antioxidant in the polymer protects it until it is depleted; then, oxidation occurs, shown by a sharp increase in the DSC baseline.
• The time from oxygen introduction to oxidation onset is called the Oxidation Induction Time (OIT).
• Also, the test can be used to access the oxidation onset temperature (OOT).

Example PP raw material with standard antioxidant package vs. PP raw material with improved antioxidant package

Figure 1 shows the result for a tested polypropylene (PP) raw material and the OIT was measured at 2.29 minutes. A second PP raw material, which contains an improved antioxidant package, showed a higher OIT (6.42 minutes), indicating better resistance to oxidation under the same test conditions [1].

Figure 1: Using DSC to estimate the anti-oxidant level in Polyolefins - Example PP [1].

Interpreting OIT Results

The OIT value alone is not meaningful, but comparing OITs of materials with similar antioxidant chemistries provides a relative measure of oxidative stability. AS a rule of thumb, higher OIT indicates better oxidative stability and, typically, higher antioxidant content.

DSC offers a quick and practical way to assess oxidative stability compared to more complex antioxidant quantification methods.

Applications of OIT measurements

Raw Material vs. Molded Part:

• Processing (molding) consumes some antioxidants, so molded parts usually have a lower OIT than raw materials. 
• Changes in processing conditions (temperature, screw speed, backpressure) affect OIT and thus the remaining antioxidant content.

Post-Processing and Environmental Effects:

• Sterilization (gamma or E-beam) can significantly reduce OIT, leading to loss of material toughness.
• Long-term heat aging also reduces OIT over time.

Conclusion

DSC-based OIT testing, despite its limitations in perfectly simulating real-world conditions, remains a valuable and practical method for comparing the oxidative stability of polyolefins. It is particularly useful for evaluating the impact of processing and post-processing on antioxidant depletion and for comparing materials with similar stabilizer chemistries.

Thanks for reading & #findoutaboutplastics

Greetings, 

Herwig Juster

🔎I review your polymer material selection and plastic part design - contact me here

🔥 There is a problem keeping you awake - My personal website for Polymer Consulting

📊 Discover your Polymer Material Selection score by taking quick test here

Literature:

[1] https://www.ptonline.com/articles/the-importance-of-oxidative-stability-in-polyolefins-part-2

The Melting Point Mystery: Identifying Polyamide 6.6 & 6 with DSC (thermal analysis)

Hello and welcome to a new blog post. Today we are diving into a powerful technique for polymer identification: Differential Scanning Calorimetry (DSC). Specifically, we will explore how DSC can help you distinguish between two common polyamides, Polyamide 6.6 (PA 6.6) and Polyamide 6 (PA 6).

What is DSC?

Differential Scanning Calorimetry (DSC) is a thermal analysis technique used to observe thermal transitions in polymers. This includes identifying key characteristics such as:

• Glass Transition Temperature (Tg): The temperature at which an amorphous polymer transitions from a rigid, glassy state to a more flexible, rubbery state.
• Melting Points (Tm): The temperature at which crystalline regions of a semi-crystalline polymer melt.
• Crystallization and Crystallization Rate: For semi-crystalline polymers, DSC can also reveal information about how they crystallize upon cooling.

The Polyamide Puzzle: PA 6.6 vs. PA 6

Imagine you have a failed injection molded part made of polyamide, but you are unsure if it is PA 6.6 or PA 6. As part of your failure analysis you need to identify the polyamide type. This is where DSC becomes incredibly handy. You can take a small piece of the part, perform a DSC analysis, and the results will provide a clear answer.

Looking at a typical DSC diagram, which plots heat flow over temperature, we can observe distinct differences between PA 6.6 and PA 6 (Figure 1):

Polyamide 6.6 (PA 6.6): This polymer typically exhibits a melting point around 268°C (approximately 270 °C). On the DSC curve, this appears as a clear, sharp peak in the higher temperature range.

Polyamide 6 (PA 6): In contrast, Polyamide 6 has a lower melting point, typically around 220 °C. Its peak will appear distinctly at this lower temperature on the DSC curve.

While both PA 6.6 and PA 6 have similar glass transition temperatures (around 50°C to 70 °C), making them less ideal for differentiation, their melting points provide a robust and clear identification.

Figure 1: Material identification using DSC - Example PA 6.6 vs PA6.

Conclusion

Using DSC to identify PA 6.6 and PA 6 by their distinct melting points is a very practical and effective method. While it requires a laboratory equipped with a DSC instrument, the clarity it provides in material identification can be invaluable for quality control, material verification, and troubleshooting in the plastics industry.

Thanks for reading & #findoutaboutplastics

Greetings, 

Herwig Juster

🔎I review your polymer material selection and plastic part design - contact me here

🔥 There is a problem keeping you awake - My personal website for Polymer Consulting

📊 Discover your Polymer Material Selection score by taking quick test here

Literature:

[1] Schadensanalyse an Kunststoff-Formteilen, VDI Verlag

Polymers and the Lindy Effect (Rule of Thumb Plastic Selection and Part Design)

Hello and welcome to a new Rule of Thumb post with focus on the Lindy Effect.

What is the Lindy Effect?

The Lindy Effect, when applied to polymers, suggests that the longer a polymer material or its application has been in use, the longer it is likely to continue to be used in the future. This effect highlights the idea that longevity in the face of time and competition implies robustness and adaptability, making older technologies or materials potentially more durable and relevant than newer, less tested alternatives. 

Examples - Polymers and the Lindy Effect

1. Established Polymer Applications: Consider the long-standing use of polyethylene (PE) in packaging or polyvinyl chloride (PVC) in construction as flame retardant flooring material as well as window frame polymer. The Lindy Effect would imply that these established uses are likely to continue for many years to come, as they have already demonstrated their longevity and reliability (Figure 1). 

Figure 1: Polymers and the Lindy Effect - Examples PVC and PE.

2. Mature Polymer Materials: Similarly, materials like natural rubber or certain types of thermosetting plastics, which have been used for a considerable time, are likely to remain relevant due to their proven track record. 

In essence, the Lindy Effect in the context of polymers suggests that the longer a polymer or its application has been around, the more likely it is to persist into the future. This is because its longevity indicates a degree of robustness and adaptability that makes it a reliable choice in the face of new innovations and changing needs. This brings me to one of my top 10 rules for plastic part design and selection (Rule Nr. 10): Past performance can be guarantee of future results. It can pay of to revisit past application designs to understand what worked in the past (materials selection and design).

Check out more Rules of Thumb in the "Start Here" section.

Thanks for reading & #findoutaboutplastics

Greetings, 

Herwig Juster

🔎I review your polymer material selection and plastic part design - contact me here

🔥 There is a problem keeping you awake - My personal website for Polymer Consulting

📊 Discover your Polymer Material Selection score by taking quick test here

Literature:

[1]  Nassim Nicholas Taleb (2012). Antifragile: Things That Gain from Disorder

High Performance Thermoplastic Selection - Polyether (PPE, PAEK, PEEK, PEKK) [Part 2C]

Hello and welcome to the Part 2C of our High Performance Thermoplastics selection blog series. Today we discuss Polyphenylene Ether (PPE) and PPE blends, their chemistry and production processes, their main properties, processing methods, and applications.

Overview - 6 major high performance thermoplastics families (“the magnificent six”) 

In this blog post series we discuss six major high performance thermoplastics families (“the magnificent six”) which are outlined in the following enumeration

1. Introduction to High Performance Polymers

2. Short profile of the "magnificent six" families:

-Part 2A: Polysulfides (Polyphenylene sulfide - PPS), Polysulfones (PSU, PESU, PPSU), and Polyarylates (PAR)

-Part 2B: Imide-Based Polymers (PEI, PAI, PESI, TPI, PI) and Polybenzimidazoles (PBI, PBI+PEEK, PBI+PEKK)

-Part 2C: Polyether (PPE, PAEK, PEEK, PEKK)

-Part 2D: Liquid Crystal Polymers (LCP) and High-performance Polyesters (Polycyclohexylene terephthalate - PCT)

-Part 2E: Semi- and Fully Aromatic Polyamides (PARA, PPA, Aramid)

-Part 2F: Polyhalogenolefins (PTFE, PCTFE, FEP, PVDF, ECTFE)

Polyphenylene Ether (PPE) and its Blends with Polystyrene (PS) and Polyamide (PA)

Polyphenylene ether (PPE), also known as polyphenylene oxide (PPO), is a high-performance thermoplastic polymer renowned for its excellent thermal, mechanical, and electrical properties. While pure PPE exhibits some processing challenges due to its high melt viscosity, blending it with polystyrene (PS) significantly improves its processability while retaining many of its desirable characteristics. These PPE/PS blends have become commercially significant engineering thermoplastics.   

Jack Welch's team at General Electric faced a challenge with Polyphenylene Oxide (PPO): its extremely high glass transition temperature (208°C) made it difficult to process without degrading the material (the methyl groups of PPE are expected to undergo autoxidation). An important key to future success was the research team around Dan Fox, Allan S. Hay, and E. M. Boldebuck, who found out the miscibility of PPO with PS first. To overcome this, they decided to blend PPO with polystyrene (PS). This clever solution allowed them to maintain many of PPO's desirable properties, lower the glass transition temperature,  while also making the material easier to process at lower temperatures and more cost-effective.

Chemistry and Production Process

1. Chemistry of Polyphenylene Ether (PPE)

The base polymer, PPE, is typically synthesized through an oxidative coupling polymerization of substituted phenols, most commonly 2,6-dimethylphenol (also known as 2,6-xylenol). This reaction is catalyzed by a copper-amine complex in the presence of oxygen. The general chemical structure of PPE can be represented as (Figure 1):

Figure 1: Chemical structure of the polymer Polyphenylene Ether (PPE) [1].

The ether linkages (-O-) in the polymer backbone, along with the aromatic rings and the methyl substituents, contribute to PPE's stiffness, thermal stability, and chemical resistance.

2. Production of PPE/PS Blends

The production of PPE/PS blends primarily involves melt blending the two polymers. This process is typically carried out in extruders or other intensive mixing equipment. The key steps include:

• Raw Material Preparation: PPE and PS resins are typically received in pellet form. They may be dried to remove any moisture before blending.
• Melt Blending: The PPE and PS pellets are fed into an extruder, where they are heated and mechanically mixed. The screw design and processing conditions (temperature, screw speed) are crucial for achieving a homogeneous blend. Compatibilizers, such as styrene-butadiene-styrene (SBS) or styrene-ethylene/butylene-styrene (SEBS) block copolymers, are often added to improve the compatibility between the relatively non-polar PS and the more polar PPE. These compatibilizers help to reduce interfacial tension and prevent phase separation, leading to enhanced mechanical properties.
• Pelletizing: The molten blend exiting the extruder is then cooled and cut into pellets, which are the final product form for subsequent processing by manufacturers.

The ratio of PPE to PS in the blend can be varied to tailor the properties of the final material to specific application requirements. Higher PPE content generally leads to better thermal and mechanical performance, while higher PS content improves processability and reduces cost (Figure 2).   

Figure 2: Changing the glass transition temperature of PPE by changing the ratio of PPE and PS [1].

Main Properties of PPE/PS Blends

PPE/PS blends exhibit a combination of properties derived from both constituent polymers, often enhanced by the presence of compatibilizers. 

Key properties include:

• Excellent Thermal Stability: PPE inherently possesses high glass transition temperatures (Tg ) and heat deflection temperatures (HDT). Blending with PS can reduce these values compared to pure PPE, however the blends still offer good high-temperature performance compared to many other engineering thermoplastics.   
• Figure 3 shows the DMA of PPE+PS blend in comparison to High Impact Polystyrene (HIPS) and Polycarbonate (PC). PS has a glass transition temperature of about 100°C and up to this temperature PPE+PS can match PC in thermal performance (PC drops sharply at Tg of 147°C). There is no sharp drop in modulus observed with PPE+PS. 

Figure 3: Dynamic Mechanical Analysis (DMA) of PPE+PS vs HIPS vs PC. 

• Good Mechanical Strength and Stiffness: PPE contributes to the blend's rigidity and strength. The impact strength can be tailored depending on the blend ratio and the use of impact modifiers.  
• Excellent Electrical Insulation Properties: PPE is an excellent electrical insulator with a low dielectric constant and high dielectric strength, which are largely retained in the blends.   
• Good Chemical Resistance: PPE offers good resistance to many chemicals, including acids, bases, and detergents. The chemical resistance of the blend is generally good but can be influenced by the PS content, which is more susceptible to certain solvents.   
• High Stability towards Hydrolysis: hydrolysis resistance of PPE is superior when compared to other engineering plastics such as PBT and PA.
• Improved Processability: The addition of PS significantly lowers the melt viscosity of PPE, making the blends easier to process using conventional methods like injection molding and extrusion.   
• Dimensional Stability: PPE contributes to low water absorption and excellent dimensional stability, which is important for applications requiring tight tolerances.   
• Flame Retardancy: PPE is inherently flame retardant. Blends often exhibit good flame retardant properties, especially when combined with flame retardant additives.   

Apart from blending PPE with PS; blends out of PPE with PA are possible too. PPE/PA blends have the following advantages: 

• Combines Key Strengths: Blends the excellent dimensional stability, low water absorption, and heat resistance of PPE with the superior chemical resistance and flow of PA.
• Enhanced Performance: The resulting material is exceptionally chemically resistant and boasts the stiffness, impact resistance, and heat performance needed for demanding applications like on-line painting.
• Significant Weight Savings: Unfilled PPE/PA blends can offer part-weight reductions of up to 25% compared to glass or mineral-filled resins, thanks to their low density.

Outperforming properties of PPE/PS blends:  

• Low specific gravity: 1.1 g/cm3. Most engineering polymers such as PC, PBT, and POM have a specific density of 1.2 g/cm3 and more. 
• High self-extinguishing property: PPE has a high oxygen index (27-29) and it is easy to add flame resistancy. 
• Excellent dielectric properties: PPE has a dielectric constant of 2.8 and a dielectric tangent of 6x1E-3. The dielectric breakdown strength (110 MV/m @ 0.5 mm thickness) is the highest among engineering plastics. 
• High dimensional accuracy: PPE has one of the lowest coefficient of linear thermal expansion among engineering polymers (5.8 x 10E-5 1/°C).

Processing Methods

PPE/PS blends can be processed using various thermoplastic processing techniques, including:

• Injection Moulding: This is the most common method for producing complex shaped parts from PPE/PS blends, leveraging their improved flow properties compared to pure PPE.
• Extrusion: These blends can be extruded into profiles, sheets, and films for various applications.  
• Blow Moulding: Certain grades of PPE/PS blends can be blow molded to produce hollow parts.
• Thermoforming: Sheets extruded from PPE/PS blends can be thermoformed into various shapes. 

Applications of PPE/PS Blends

The unique combination of properties makes PPE/PS blends suitable for a wide range of applications across various industries:

• Construction and Plumbing: Applications include pump housings, impellers, and other components requiring good mechanical and chemical resistance.
• Automotive Industry: Interior and exterior components such as instrument panels, door panels, wheel covers, and electrical connectors benefit from the blends' thermal stability, dimensional stability, and impact resistance.   
• Electrical and Electronics: Housings for electrical connectors, circuit breakers, switchgear, and other electrical components utilize the excellent electrical insulation properties and flame retardancy of PPE/PS blends.   
• Household Appliances: Components for washing machines, dishwashers, microwave ovens, and other appliances benefit from the blends' heat resistance, chemical resistance, and good mechanical properties.
• Business Equipment: Housings and internal components for computers, printers, and other office equipment utilize the blends' dimensional stability, electrical properties, and aesthetic appeal.   
• Healthcare: Certain grades of PPE/PS blends can be used in medical devices and equipment due to their sterilizability and chemical resistance.   

Trade Names

Several companies market PPE/PS blends under various trade names. Some well-known examples include:

• Noryl™: Formerly a trademark of GE Plastics, now owned by SABIC Innovative Plastics. This is one of the most widely recognized families of PPE-based resins, including various PPE/PS blends and other modifications.
• XYRON™ from Japanese chemical company Asahi Kasei.
• Various manufacturers such as Global Acetal (Lemalloy PPE) produce generic PPE/PS blends with specific property profiles.   

Economic Aspects

The market for PPE/PS blends is significant within the broader engineering thermoplastics market. The demand is driven by the increasing need for high-performance materials in automotive, electronics, plumbing and appliance industries.   

• Cost Factors: The cost of PPE/PS blends is influenced by the price of the base polymers (PPE and PS), the concentration of PPE in the blend, the type and amount of compatibilizers and additives used, and the manufacturing process. Generally, higher PPE content leads to higher costs.
• Market Trends: The trend towards lightweighting in the automotive industry and miniaturization in electronics continues to drive the demand for materials like PPE/PS blends that offer a balance of performance and processability. Growing environmental concerns are also pushing for more sustainable material solutions, which may influence the development of new PPE-based blends with recycled content or improved recyclability.
• Regional Variations: The demand and market dynamics for PPE/PS blends can vary across different geographical regions based on industrial activity and specific application needs.

In conclusion, polyphenylene ether (PPE) and its blends with polystyrene and polyamide represent a versatile class of engineering thermoplastics offering a compelling combination of high-performance properties and improved processability. Their wide range of applications across various industries underscores their economic and technological significance in the world of polymer engineering. As a polymer engineering student, understanding the nuances of these materials will undoubtedly be valuable in your future endeavors.   

In the upcoming Part 2C we will continue to discuss the Polyether high performance polymers such as PAEK, PEEK, and PEKK.

Thanks for reading & #findoutaboutplastics

Greetings, 

Herwig Juster

🔎I review your polymer material selection and plastic part design - contact me here

🔥 There is a problem keeping you awake - My personal website for Polymer Consulting

📊 Discover your Polymer Material Selection score by taking quick test here

Literature: 

[1] Allan S. Hay: Polymerization by Oxidative Coupling: Discovery and Commercialization of PPO and Noryl Resins

[2] https://www.sabic.com/en/products/specialties/noryl-resins

[3] https://www.gpac.co.jp/en/product/lemalloy/

[4] https://www.findoutaboutplastics.com/2016/09/jack-welch-and-his-uprise-in-ge.html

[5] https://www.findoutaboutplastics.com/2024/08/high-performance-thermoplastic.html

The Sticky Truth About Gluing Plastics: Why Surface Energy Matters (Plastics Processing Rule of Thumb)

Hello and welcome to todays post focusing on gluing plastics.  Ever tried to glue two pieces of plastic together, only for the bond to fail miserably? You're not alone! Gluing plastics can be surprisingly tricky, and a key factor often overlooked is something called surface energy. Think of surface energy as how "eager" a material's surface is to bond with something else. And when it comes to adhesives, eagerness is a good thing!

The Rule of Thumb: High Surface Energy = Stronger Bonds

Here's the golden rule for gluing: the higher the surface energy of a material, the greater the strength of the adhesion you can achieve.

Imagine a tiny water droplet on a surface. On a highly energetic surface, the water spreads out, trying to maximize its contact. On a low energy surface, it beads up, shrinking away. Adhesives behave similarly. They want to spread out and "wet" the surface completely to form a strong bond.

Diving Deeper: High vs. Low Surface Energy Plastics

Plastics are generally categorized into two main groups when it comes to surface energy:

• High Surface Energy (HSE) Plastics: These plastics are generally easier to bond. Their surfaces are more receptive to adhesives, allowing for better "wetting" and stronger molecular interactions.
• Low Surface Energy (LSE) Plastics: These are the notorious "difficult-to-glue" plastics. Their surfaces are less receptive, causing many common adhesives to bead up and struggle to form a lasting bond.

A Quick Look at Surface Energy Values (mJ/m²)

To give you a better idea, below is a small table (Table 1) with approximate surface energy values for some common plastics and other materials. Remember, these values are guides, and specific formulations can impact them.

Table 1: Overview of surface energy values of plastics [1].

As you can see, materials like PTFE (often known as Teflon) have very low surface energy, making them incredibly challenging to bond without specialized adhesives or surface treatments. Another example is the high performance polymer PPS. The surface energy of untreated polyphenylene sulfide (PPS) is typically around 38 mJ/m2. This relatively low surface energy makes PPS challenging to bond to other materials without surface treatment. However, PPS can be treated to increase its surface energy, such as through plasma treatments, which can raise the surface energy to 38 mJ/m2 or higher, depending on the treatment method. In contrast, materials like Polyimide are much more accommodating.

What Does This Mean for Your Next Plastics Gluing Project?

When you're facing a plastic gluing challenge, keep this rule of thumb in mind:

1. Material selection: list gluing as a post-processing operation during part requirement analysis.
2. Identify the Plastic: If you know the type of plastic, you can often infer its surface energy.
3. Opt for HSE Plastics When Possible: If you have a choice of materials, pick higher surface energy plastics for easier and more reliable bonds.
4. Specialized Adhesives for LSE Plastics: For low surface energy plastics, don't reach for your all-purpose super glue. You'll likely need specialized adhesives designed for LSE materials, or consider surface preparation techniques (like primers or plasma treatment) to temporarily increase the surface energy.

Conclusiones

Understanding surface energy is a game-changer for anyone working with adhesives and plastics. By keeping this simple principle in mind, you'll significantly improve your chances of achieving strong, long-lasting bonds and avoid those frustrating gluing failures. Happy gluing!

More Rule of Thumbs can be found in the section "Start here".

Thanks for reading and #findoutaboutplastics

Greetings

Herwig Juster

🔎I review your polymer material selection and plastic part design - contact me here

🔥 There is a problem keeping you awake - My personal website for Polymer Consulting

📊 Discover your Polymer Material Selection score by taking quick test here

Literature: 

[1]https://www.3m.com/3M/en_US/bonding-and-assembly-us/applications/material-bonding/engineered-plastics/

[2] https://www.findoutaboutplastics.com/2025/04/nature-is-built-on-5-polymers-modern.html

Design Data for Engineers: Thermal Aging of PPS Compounds

Hello and welcome to today’s blog post on thermal aging of PPS compounds. During material selection, focus on gathering and understanding all the requirements of the application is essential. Key questions to answer are: What is the service environment of your part? And also: What types of load at which service temperature and time need to be fulfilled?

Thermal aging of Polyphenylene sulfide (PPS) compounds (glass; glass/mineral filled)

High performance polymers such as Polyphenylene sulfide (PPS) offer excellent performance during high heat exposure. PPS mouldings, both filled and unfilled, maintain inherent flame resistance and excellent chemical resistance due to the base resin.

Long-term heat aging results align with the polymer's thermal stability. PPS has a UL 746B continuous use temperature (CUT) of 220°C. It is in a similar range with PPSU which has a CUT of 210°C and PTFE is even above 230°C. 

Figure 1 highlights the good retention of tensile properties in glass and glass/mineral-filled compounds over long-term exposure. An aging test was performed at two temperatures (175°C and 230°C) for a maximum duration of 10,000 hours [2]. 

Figure 1: Thermal aging of PPS compounds (175°C and 230°C; 10,000 hours).

Due to the curing characteristics of cross-linked PPS, aging at temperatures above those in Figure 1 can enhance property retention, attributed to a "case hardening" effect from high-temperature air exposure.

At elevated temperatures, PPS compounds show classical deterioration beyond their glass transition temperature (Tg). Despite crystallinity effects, strength loss is gradual, with significant integrity retained even at 200°C. PPS compounds filled with glass and mineral can retain the tensile properties at both temperatures at a higher level (80% retention rate) compared to glass fiber reinforced PPS compounds (60% retention rate).

Generally, 40% glass-filled mouldings retain about 80% of their original strength at 100°C, 60% at 160°C, and 40% at 200°C.

Conclusion

In conclusion, Polyphenylene sulfide (PPS) compounds demonstrate exceptional performance under high heat exposure, making them a reliable choice for applications requiring thermal stability. Both filled and unfilled PPS moldings exhibit inherent flame resistance and chemical resistance, aligning with the polymer's robust thermal properties. The long-term heat aging results confirm PPS's ability to retain tensile properties, even at elevated temperatures. With a continuous use temperature of 220°C, PPS stands out among high-performance polymers, maintaining significant strength and integrity over time. This makes PPS an excellent candidate for applications demanding durability and reliability in challenging thermal environments. When selecting materials, it is crucial to thoroughly understand the application's requirements, including service environment, load types, and service temperatures, to ensure optimal performance and longevity.

Thanks for reading and #findoutaboutplastics

Greetings

Herwig Juster

🔎I review your polymer material selection and plastic part design - contact me here

🔥 There is a problem keeping you awake - My personal website for Polymer Consulting

📊 Discover your Polymer Material Selection score by taking quick test here

Literature: 

[1] https://www.findoutaboutplastics.com/2024/09/high-performance-thermoplastic.html

[2] Don Brady: Polyphenylene sulfide (PPS), Phillips Petroleum Company

Glass-Fiber Filled PET vs. PBT: Choosing the Champion for Your Application

Hello and welcome to a new blog post. In this post we are comparing glass-fiber filled PET vs. PBT, especially heat distortion properties (HDT). We dive into why PET's higher stiffness, heat resistance, and lower water uptake can be a game-changer for E&E and metal replacement applications. It can help you to elevate your material selection process - let us get started!

PET compounds vs PBT compounds

When it comes to high-performance engineering plastics, glass-fiber reinforced compounds of PET (Polyethylene Terephthalate) and PBT (Polybutylene Terephthalate) are often top contenders. While both offer enhanced strength and rigidity, their distinct properties can make one a clear winner over the other for specific demands. 

One of PET's significant advantages lies in its higher stiffness, which directly translates to reduced creep under sustained loads. This superior mechanical integrity ensures long-term performance where dimensional stability is critical. Furthermore, PET compounds boast a notably higher heat distortion temperature (HDT). Specifically, when measured with HDT/B, PET can exhibit a delta of up to 20°C higher than PBT, making it more resilient in high-heat environments (Figure 1).

Figure 1: Comparison of HDT/A and HDT/B of PET-GF30 and PBT-GF30

Another crucial differentiator is PET's lower water uptake. This property directly contributes to better dimensional stability, as the material is less prone to swelling or warping in humid conditions. In the realm of electrical and electronic (E&E) applications, glass-fiber filled PET truly shines due to its good dielectric properties and the potential for achieving high UL RTI (Relative Thermal Index) values. These characteristics ensure reliable insulation and performance at elevated temperatures.

These combined attributes—superior stiffness, higher heat resistance, better dimensional stability, and excellent electrical properties—make glass-fiber filled PET compounds particularly compelling for demanding applications in the E&E industry. They are also an excellent choice for metal replacement, offering a lighter, often more cost-effective, and corrosion-resistant alternative without compromising on critical performance metrics. When designing your next component, understanding these nuances can lead to superior product design and longevity.

Thanks for reading and #findoutaboutplastics

Greetings

Herwig Juster

🔥 There is a problem keeping you awake - My personal website for Polymer Consulting

📊 Discover your Polymer Material Selection score by taking quick test here

Literature:

[1] https://www.findoutaboutplastics.com/2025/05/4-tips-for-effective-polymer-material.html

[2] https://www.celanese.com/products/rynite-pet

[3] https://www.findoutaboutplastics.com/2025/05/pet-grade-selection-for-diverse.html

[4] https://www.polymermaterialselection.com/selection-examples-blog