Monday, 16 February 2026

📚 My new book, "Pumping Plastics 2025," is out now! Available as Paperback Worldwide on Amazon!

Dear coomunity, welcome to “Pumping Plastics 2025”—Your Essential Guide to the World of Modern Polymers!

Are you ready to dive into the dynamic world of plastics and polymers? 

This book brings together all the insightful posts from my 2025 FindOutAboutPlastics.com blog, curated to help you stay ahead in the fast-evolving plastics industry.

  • Inside, you’ll discover a rich collection of topics, including:
  • The latest in injection molding and processing techniques
  • Practical strategies for polymer selection and comparison
  • Fresh perspectives on materials science and industry trends
  • Inspiring stories of sustainability and innovation
  • Career tips and real-world advice for plastics professionals
  • Engineering insights, design best practices, and failure analysis
  • Special features and thought-provoking inspiration

Whether you prefer to read month by month or jump straight to the topics that spark your curiosity, this book is designed for flexible, practical learning. And as a special bonus, you’ll find the first chapter of my acclaimed book, “Polymer Material Selection,” included to kickstart your journey.

Let “Pumping Plastics” be your trusted companion—whether you’re a student, engineer, or industry veteran—on the path to mastering the science, art, and business of plastics.

Grab your copy here and stay ahead of the curve!

Thanks for reading & #findoutaboutplastics

Greetings,

Herwig Juster


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Tuesday, 10 February 2026

Plastics and Polymers Selection for Humanoid Robot Applications: From Structural Skeletons to Artificial Muscles



Hello and welcome to a new material selection post in which we discuss suitable plastics for humanoid robotic applications. It is a longer post and I have structured it into five chapters: 

  • Chapter 1: The Humanoid Market – From Industrial Tools to Bio-mimicry
  • Chapter 2: The Structural Skeleton – PEEK and Reinforced Composites
  • Chapter 3: The “Artificial Muscle” – Electroactive Polymers (EAPs)
  • Chapter 4: Actuation and Tribology – Gears, Wear, and Sealing
  • Chapter 5: The PFAS Challenge – Engineering Without “Forever Chemicals”

Introduction

Humanoid robots represent one of the most demanding convergence points of mechanical engineering, electronics, materials science, and biology-inspired design. Unlike traditional industrial robots, humanoids must be lightweight, energy-efficient, safe for human interaction, and capable of complex, biomimetic motion.

In this context, optimal polymer selection is a key engineering decision. The correct choice of plastic materials is essential to:

  • Ensure reliable function of all robot subsystems

  • Balance stiffness, weight, wear resistance, and durability

  • Prevent premature part failure due to fatigue, creep, wear, or environmental exposure

Poor material selection can lead to unexpected breakdowns, excessive wear, thermal deformation, or regulatory non-compliance, often only discovered late in development or during field operation.

Polymers and polymer-based composites are no longer auxiliary materials in this space — they are enablers. This article explores how advanced plastics underpin modern humanoid robot design, from structural frames to artificial muscles, while addressing emerging regulatory and sustainability challenges.

Chapter 1: The Humanoid Market – From Industrial Tools to Bio-mimicry

Market Context: From Cobots to Autonomous Humanoids

Early collaborative robots (“cobots”) were essentially industrial manipulators made safer through sensors and control algorithms. Their material choices reflected this heritage: steel, aluminum, and classical engineering plastics.

Today’s humanoid robots represent a paradigm shift:

  • Designed for unstructured environments

  • Expected to interact safely with humans

  • Required to move with human-like kinematics

  • Increasingly autonomous, powered by onboard batteries

This shift has forced engineers to rethink mass distribution, inertia, and energy efficiency — areas where polymers outperform metals.

Design Step: Lightweighting as a System-Level Strategy

In humanoid robots, weight is not neutral:

  • Every gram saved in the frame can be reassigned to:

    • Battery capacity (longer runtime)

    • Sensors and AI hardware

    • Payload capability

Polymers enable functional integration (snap-fits, ribs, channels, cable guides) that would require multiple machined metal parts, thereby reducing both part count and mass.

Chapter 2: The Structural Skeleton – PEEK and Reinforced Composites

Material Focus: High-Performance Structural Polymers

The “skeleton” of a humanoid robot must provide high stiffness, fatigue resistance, and dimensional stability under cyclic loads.

Key materials include:

  • PEEK (Polyetheretherketone)

    • Carbon- or glass-fiber reinforced

    • Exceptional stiffness-to-weight ratio (interesting for metal replacement)

    • High thermal stability and chemical resistance

    • Structural frames, gears, joints, bushings, insulation

  • PA 6.6 (Polyamide 6.6)

    • Tough, cost-effective

    • Suitable for secondary load-bearing structures, housings, covers

    • 3D printing possible (SLS)

    • PolyArylAmide (PARA, PA-MXD6): for appliactions in robotics where low moisture, high dimensional stability (enabling complex parts), excellent surface appearance (“best-in-class” among the Polyamides), and outstanding stiffened and strength is needed.

  • Polycarbonate (PC)
    • Impact-resistant, transparent, stable
    • Sensor/camera covers, shields, panels

  • PPS (Polyphenylene Sulfide)

    • Glass-fiber reinforced

    • Excellent dimensional stability

    • High thermal and creep resistance

    • Connectors, housings, parts near heat sources

  • PEI (Polyetherimide)
    • High strength, flame retardant, heat resistant, good electrical properties
    • Connector housings, structural frames
    • Strong, safe, reliable in harsh environments

  • LFT (Long Fiber Thermoplastics)

    • Continuous or long glass/carbon fibers

    • Ideal for large, injection-molded structural parts

    • High load capacity, reduces robot weight

Design Example: Replacing Aluminum with CNC-machined or 3D-printed PEEK

CNC-machined or 3D-printed carbon-filled PEEK can achieve:

  • Elastic modulus approaching aluminum

  • Up to 50% weight reduction

  • Significantly lower rotational inertia

Lower inertia directly translates into:

  • Faster acceleration and deceleration

  • Reduced motor size

  • Lower energy consumption

Additive manufacturing further enables topology-optimized structures, closely mimicking biological bones with hollow cores and load-aligned fiber orientations.

Chapter 3: The “Artificial Muscle” – Electroactive Polymers (EAPs)

Defining EAPs

Electroactive Polymers (EAPs) are materials that change shape, size, or mechanical properties when subjected to an electrical stimulus. They are often described as “muscle-like” materials because their actuation principles resemble biological muscle contraction.

Electronic vs. Ionic EAPs

Electronic EAPs

Examples:

  • Dielectric Elastomers (DEAs)

  • Electrostrictive Graft Elastomers

  • Ferroelectric Polymers

Characteristics:

  • Fast response times

  • High energy density

  • Require high operating voltages

  • Suitable for dry environments

Ionic EAPs

Examples:

  • Ionic Polymer-Metal Composites (IPMCs)

  • Conducting Polymers

  • Carbon Nanotube (CNT) networks

Characteristics:

  • Operate at low voltages

  • Slower response

  • Often require moisture or electrolytes

  • Ideal for fine, low-force movements


Design Example: Eliminating Gears and Motors

EAPs enable soft robotics, where motion is achieved without:

  • Gearboxes

  • Bearings

  • Lubricants

Applications include:

  • Facial expression systems

  • Dexterous fingers

  • Artificial skin and haptics

The result is silent, compliant, and lifelike motion, impossible to achieve with rigid electromechanical systems alone.

Chapter 4: Actuation and Tribology – Gears, Wear, and Sealing

Motion Control: Tribological Plastics

Despite advances in soft actuation, many humanoid joints still rely on conventional rotary actuation. Here, tribological performance is critical.

Key materials:

  • POM (Acetal) – low friction, dimensional stability

  • PA 4.6 – high melting point, excellent fatigue resistance

  • PA 6.10 – outstanding wear resistance

  • Polyketone & PEEK – good wear resistance: Polyketone, as an example,  has a 14 times higher anti-abrasion property compared to POM, allowing for almost permanent use without change.

  • Self-lubricating materials using fillers such as Graphite, Molybdenum Disulfide (MoS2), Carbon fiber, and PTFE/UHMWPE – maintenance-free bearings and joints

These materials allow:

  • Dry-running systems

  • Reduced maintenance

  • Long service life under oscillating motion

Sealing: Protecting Sensitive Electronics

Humanoid robots operate in dusty, humid, and unpredictable environments. Advanced sealing systems are essential.

  • IPSR (Ingress Protection Seals) / PSS (Precision sealing systems)

  • Advanced EPDM, NBR and FKM elastomers

  • High-temperature thermoplastics such as Quantix® ULTRA (1.200 °C)

These seals protect:

  • Motors

  • Sensors

  • Control electronics
    …without adding excessive friction or bulk.

Chapter 5: The PFAS Challenge – Engineering Without “Forever Chemicals”

The Regulatory Hurdle

Historically, many high-performance plastics relied on PTFE additives to reduce friction and wear. However:

  • PTFE belongs to the PFAS ( Per- and polyfluoroalkyl substances) containing family

  • Increasingly restricted under REACH / ECHA and EU 2019/1021

  • Long-term environmental persistence (“forever chemicals”)

This has forced a fundamental rethink of tribological design.

The Innovation Step: Molecular Engineering

Instead of relying on fluorinated additives, modern polymers achieve performance through intrinsic molecular structure.

A prime example:

  • PA4.6

    • Higher melting point than PA 6 or PA 6.6

    • Superior crystallinity (80%)

    • Excellent fatigue and wear resistance

    • Performs under high speed and load without PTFE

This enables PFAS-free gears and bearings suitable for humanoid robot actuators.

Apart from PA 4.6, there are polymers which are inherently wear-resistant too: 

-Polyketone (PK)

-Polyoxymethylene (POM): crystallinity level above 90% possible

-Ultra-high molecular weight polyethylene (UHMWPE)

-Polyamide-Imide (PAI)

-Polybenzimidazole (PBI)

-Polyetheretherketone (PEEK)

As alternative, Hexagonal boron nitride (hBN) which can offer a fluorine- and micro plastic-free replacement. The very good lubricating properties of hBN come from its crystal structure. We discussed this in detail with Michaela Schopp - Product Manager at Henze BNP AG in this guest interview here.

Conclusion

The selection of high-performance plastics in humanoid robotics is driven by the need for lightweight, durable, and reliable components that can withstand mechanical stress, environmental exposure, and regulatory requirements. Materials like PEEK, PA, PC, POM, PPS, PEI, PU, and LFT each offer unique advantages for specific robot parts, from structural frames to gears and sensor housings (Figure 1). As the robotics industry evolves, the role of advanced, sustainable polymers will only increase, enabling the next generation of agile, efficient, and compliant humanoid robots.

Figure 1: Summary of materials used for Humanoid Robotic applications.

If you need selection support, or a deeper dive into a specific material or application, please let me know!

Thanks for reading & #findoutaboutplastics

Greetings,

Herwig Juster

Literature: 

[1] https://www.fst.com/de/news-stories/pressemitteilungen/2024/thermoplaste-fuer-bis-zu-1200-grad-celsius/

[2] https://www.fst.com/markets/robotics/6-axis-robot/

[3] https://toolbox.igus.com/motion-plastics-blog/understanding-the-humanoid-robot-market/?pk_vid=1727719344ad05051727719347ad0505
[4] https://toolbox.igus.com/motion-plastics-blog/maximizing-humanoid-robot-longevity/?pk_vid=1727719906ad0505
[5] https://www.peekchina.com/blog/plastics-for-humanoid-robots.html
[6] https://www.lft-g.com/blog/peek-the-ultimate-lightweight-material-for-humanoid-robots_b210
[7] https://www.fst.com/news-stories/robotics/humanoid-robots/
[8] https://www.honyplastic.com/news/eight-major-polymer-materials-used-in-humanoid-robots-309468.html
[9] https://www.therobotreport.com/envalior-offers-pfas-free-materials-wear-friction-applications/
[10] https://www.protolabs.com/en-gb/resources/blog/materials-that-command-the-robotics-industry/
[11] https://www.zhongyanpeek.com/peek-composite-materials-reshape-the-future-of-industry-and-humanoid-robots.html
[12] https://schunk.com/de/de/news/schunk-gruendet-tech-spin-off-fuer-humanoide-roboterhaende/36224
[13] https://www.linkedin.com/pulse/syensqos-ketaspire-peek-enables-durability-flexible-joints-baleno-5oj9c/?trackingId=DBuQvo0eWn86WUTpTpAECQ%3D%3D
[14] https://www.dreyplas.com/en/polyketone/
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Tuesday, 3 February 2026

Blending Virgin Plastic Resins with Regrind/Recycled Materials - Checklist for Plastic Processors

Hello and welcome to a new blog post in which I provide you with a checklist on blending virgin plastic resins with regrind or recycled materials. 

Introduction

In today’s plastics industry, blending virgin resins with regrind or recycled materials is a powerful way to enhance sustainability and reduce costs. However, achieving consistent quality and performance requires careful attention to every step of the process.

To support your operations, we’ve developed a practical checklist (Figure 1) highlighting the 10 most important points to consider when blending virgin plastics with regrind or recycled content. Whether you’re optimizing for efficiency, compliance, or product quality, this checklist will help you avoid common pitfalls and ensure reliable results.

Use this tool as a guide to streamline your workflow, maintain high standards, and drive continuous improvement in your plastics processing. Remember: customizing these checks to your specific materials and processes will yield the best outcomes.

Figure 1: Checklist - Blending virgin plastic with regrind/recyled plastics.

Check out also this post: How to Mark Plastic Parts with Recycled Content: A Quick Guide to ISO 1043 & ISO 11469

Thanks for reading & #findoutaboutplastics

Greetings,

Herwig Juster

Literature:

[1] https://www.findoutaboutplastics.com/2023/07/plastic-part-design-for-recycling.html

[2] https://www.findoutaboutplastics.com/2023/04/guest-interview-bianca-gubi-product.html



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Tuesday, 27 January 2026

Personal Update: I have officially obtained my ISO/IEC 17024 Expert Witness certification specializing in plastics and plastic products

Hello and welcome to this personal update post. I am pleased to announce that I have officially obtained my ISO/IEC 17024 Expert Witness certification specializing in plastics and plastic products. 

Smiling for the camera with my freshly obtained ISO/IEC Expert Witness Certificate, together with the "Brick Moulding Machine" (© Herwig Juster)

Why does ISO/IEC 17024 matter in 2026?

The complexity of polymer science and engineering is increasingly at the heart of high-stakes litigation—from IP disputes and product liability to the emerging legal challenges of the circular economy.

The ISO/IEC 17024 represents an international gold standard for technical competence and—most importantly—procedural objectivity. In an era where expert testimony is under microscopic scrutiny, I provide a defensible, audited methodology to every case.

My Core Focus Areas:
  •  Plastics Failure Analysis & Root Cause (ESCR, Fatigue, Degradation)
  •  Intellectual Property & Patent Disputes
  •  Product Liability & Personal Injury 
  • Specialized Niche: Liability and failures in Recycled Plastics (PCR/PIR) including processing analysis (extrusion and injection molding).
Whether you are in the discovery phase or need an early-stage technical viability assessment, my goal is to bridge the gap between complex material science and the requirements of the court.

What's next?

Step by step I will roll out my dedicated Plastics Expert Witness landing page, and I am developing a "Case Viability Scorecard" which helps you to determine if your case is a fit for me - stay tuned. 

My certification is valid for five years and can be online checked at the EUCert via this link.

If you want to get in contact with me to discuss your case you can reach me here too 

Thanks for reading & #findoutaboutplastics

Greetings,

Herwig Juster



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Monday, 19 January 2026

20 Mental Models for effective thinking in- and outside the plastics industry

Hello and welcome to a new blog post. Today we cover mental models and why the are not only important for us in polymer engineering, but also for private and other professional areas of life too.

In 2026, mental models—conceptual, often simplified frameworks for understanding the world—are critical for navigating a landscape defined by rapid AI advancement, geopolitical instability, and extreme information saturation. They serve as "cognitive toolkits" that allow individuals and leaders to parse complex, ambiguous data into actionable decisions. 

Mental models are important in 2026 for the following key reasons:

1. Navigating Complexity and AI-Augmented Environments

  • Example - Cutting Through "Noise": With AI generating massive amounts of data, mental models help filter information and focus on high-impact factors (e.g., using the Pareto 80/20 Rule to identify crucial data points).
  • Example - Contextualizing AI Outputs: As AI becomes ubiquitous in 2026, human judgment remains essential for interpreting AI insights; mental models provide the necessary framework for this contextualization.
  • Example - Systems Thinking: Understanding how different components (remote work, global supply chains, AI tools) interact is crucial. Systems thinking helps identify patterns and leverage points for change rather than reacting to symptoms. 

2. Professional Adaptability and Decision Speed

  • Example - Rapid Decision Making: In 2026, business leaders must make decisions 2.5 times faster than competitors. Mental models (like the OODA Loop—Observe, Orient, Decide, Act) enable swift, effective, and reasoned actions under pressure.
  • Example - Mitigating Cognitive Bias: The fast-paced environment increases the risk of emotional or faulty decision-making. Mental models like Inversion (considering how to avoid failure) or Second-Order Thinking (evaluating long-term consequences) allow for more objective, strategic choices.
  • Example - Increased "Model Literacy": Success in 2026 requires understanding multiple mental models across disciplines—a "latticework" that allows for more versatile, creative problem-solving rather than relying on a single, outdated framework. 

3. Personal Resilience and Growth

  • Example - Managing Cognitive Load: The sheer volume of information can cause "cognitive fatigue." Mental models help organize information and reduce the mental effort required to make sense of new, complex situations.
  • Example - Developing Emotional Stamina: As global instability creates stress, mental models assist in building emotional resilience and maintaining a "growth-oriented" perspective, allowing individuals to adapt to change rather than being overwhelmed by it.
  • Example - Lifelong Learning: In 2026, continuous learning is essential for career longevity. Mental models facilitate the learning of new concepts by connecting them to existing knowledge, accelerating the transition from novice to expert. 

4. Improved Collaboration 

  • Example - Shared Mental Models: In hybrid and remote work environments (which are standard by 2026), shared mental models enable teams to align on goals and expectations, leading to more cohesive and efficient collaboration. 

My 20 Mental Models for Effective Thinking

Over the past decade of my career in polymer engineering, I have systematically collected and applied a range of mental models to enhance my professional effectiveness. In the accompanying sketchnote (Figure 1), I have outlined the 20 mental models I utilize most frequently. 

These models are categorized into four key areas: Core Frameworks, Decision Making and Bias, Change and Adaptation, and System and Interaction.

Figure 1: 20 Mental Models for effective thinking in- and outside plastics industry

In summary, as we move through 2026, mental models are no longer optional, abstract concepts; they are the essential, daily tools for maintaining clarity, speed, and sanity in a rapidly evolving (plastics) world. 

Thanks for reading & #findoutaboutplastics

Greetings,

Herwig Juster

Literature:

[1] https://tetr.com/blog/mental-models-for-business-success-secrets-for-aspiring-founders#:~:text=Mental%20models%20are%20cognitive%20frameworks,identify%20patterns%20others%20might%20miss.

[2] https://taproot.com/mental-models/#:~:text=Simplifying%20Complexity:%20In%20today's%20fast,productive%20discussions%20and%20innovative%20solutions.

[3] https://medium.com/@chamiduweerasinghe/the-future-of-personal-development-trends-to-monitor-in-2026-and-beyond-0537609878f8#:~:text=Companies%20that%20invest%20in%20building,Technology%20as%20the%20Growth%20Engine

[4] https://academic.oup.com/ct/article/35/4/250/8166013#:~:text=These%20models%20map%20onto%20elements,.%2C%202004%2C%202007).

[5] https://modelthinkers.com/mental-model/mungers-latticework

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Friday, 9 January 2026

AI & Machine Learning Transforming the Plastics Value Chain

Hello and welcome to a new blog post. AI and machine learning are rapidly transforming every stage of the plastics value chain—from material innovation to recycling and sustainability. 

Introduction

Just as elephants in Africa can sense approaching storms and tsunamis before they arrive—prompting smaller animals to follow their lead—the plastics industry is witnessing its own early warning signs. Today, the “big elephants” of the economy—major tech companies—are already on the move, rapidly embracing AI and machine learning to transform every stage of the plastics value chain. If we want to keep pace and avoid being left behind, now is the time to act.

AI & Machine Learning Transforming the Plastics Value Chain

In this sketch note, I explore how AI is accelerating polymer research, revolutionizing part design, optimizing manufacturing, and enabling smarter, more sustainable choices across the industry. 

Whether you’re in R&D, engineering, production, or sustainability, discover practical examples and key takeaways on how AI is reshaping the future of plastics. 

Don’t wait for the storm to hit—see how your organization can leverage these advancements for a competitive edge!

AI and Machine Learning: Transforming the plastics value chain.

AI & Machine Learning Transforming the Plastics Value Chain

1) Material Development and Polymer Innovation

AI and machine learning (ML) are actively accelerating materials research, enabling predictive modeling of polymer properties, virtual screening of candidates, and synthetic data generation to overcome experimental gaps. This approach dramatically speeds up the discovery of sustainable and high-performance plastics. 

In advanced research, machine learning models have been used to design crosslinker strategies that strengthen polymer networks and could be applied to real industrial plastics to reduce waste and extend service life. 

Emerging tools are focused on materials that combine sustainability with performance (e.g., biodegradable or recyclable polymers), addressing long-standing limitations in replacing conventional plastics. 

Practical engineering implications

  • R&D teams can leverage AI to predict key material properties like glass transition temperature or tensile strength without exhaustive lab trials.
  • Material selection and optimization become data-driven, reducing development cycles and enabling tailored polymer solutions in automotive, medical, and packaging applications.

2) AI in Part Design, Material Selection & Engineering Decision Support

AI platforms such as plastics.ai offer curated, domain-specific expert knowledge tied to practical plastics technology (including material choice, defect mechanisms, processing answers) with transparent source backing — a major shift from generic LLMs toward validated engineering assistance. 

ML-augmented digital twin technologies and simulations can reduce prototype cycles by allowing engineers to explore variations in part geometry, polymer grades, and processing conditions in silico before physical testing. 

Practical engineering implications

  • Engineering design teams can integrate AI tools to automate material performance predictions, compare alternatives, and flag potential manufacturability issues before mold design and process planning.
  • AI-assisted design accelerates concept-to-production timelines and supports optimized material selection for durability, weight, and recyclability trade-offs.

3) AI & Digitalisation in Processing and Production

Autonomous Injection Molding (Processing Optimization)

Companies like ENGEL are showcasing inject AI and autonomous injection moulding cells — systems that continuously analyze over 1,000 process parameters, adjust cycle conditions in real time, and reduce scrap and setup times. 

These systems embed decades of application engineering into the control layer, making consistent quality achievable without deep expert intervention on the shop floor. 

Practical engineering implications

  • Process engineers can use AI to reduce dependence on individual experts by capturing and distributing best-practice expertise across operations.
  • AI-based control enables zero-defect strategies, consistent cycle times, reduced energy use, and lower reject rates — directly impacting productivity and sustainability goals.

Predictive Maintenance & Process Automation

Across manufacturing, AI is deployed for predictive maintenance, where sensors and ML forecast equipment degradation before failures, cutting unplanned downtime. 

Practical engineering implications

  • Maintenance planning shifts from reactive to proactive, increasing uptime, extending machine life, and enabling better capacity planning.

4) AI & Recycling, Circularity, and Sustainability

Sorting and Recycling Optimization

AI and ML-enhanced spectroscopic sorting solutions are improving accuracy and throughput in recycling streams, particularly for mixed plastics — a major bottleneck in circularity. 

Research labs and industry collaborations are building AI-driven frameworks that interconnect data from recycled feedstocks to packaging production, choosing optimal processes in real time for quality outcomes. 

Practical engineering implications

  • Recycling engineers benefit from higher fidelity sorting, reducing contamination and increasing recyclate quality, supporting higher recycled content in products.
  • Real-time decision tools enable processors to adapt extrusion, molding, or compounding recipes depending on fluctuating quality of input recyclates.

Circularity Platforms & Tools

The launch of tools like the KIKS open beta platform applies machine learning to the entire value chain, offering material substitution suggestions, predictive property data, and analytics support for composite design and sustainable choices. 

Practical engineering implications

  • Value chain stakeholders — from compounders to OEMs — can streamline sustainability decisions, evaluate alternatives rapidly, and reduce reliance on manual material data curation.

5) Sectoral & Strategic Impact (Industry Outlook)

Broader industry data (e.g., Deloitte chemical industry outlook) indicates that AI and digital technologies are a core element of resilience and transformation strategies for the chemicals and plastics sectors amidst economic uncertainty. AI is increasingly used to optimize operations, reduce energy consumption, enhance safety, and accelerate commercialization of new materials.

Practical engineering implications

  • Companies that embed AI in R&D, process platforms, and end-to-end digital strategies will be best positioned to navigate market volatility and regulatory pressures.
  • Digital maturity — including AI integration — is becoming a competitive differentiator rather than optional IT add-on.

6) Challenges & Enablers for SMEs and Engineering Organizations

Adoption barriers remain significant for small and medium enterprises (SMEs), including data quality issues, lack of expertise, and legacy system incompatibility. However, public funding programs and strategic digitalization roadmaps can ease adoption and unlock competitive benefits. 

Practical strategies emphasize starting with low-code and cloud-based AI tools, aligning with current IT environments, and focusing on use cases that return near-term value (e.g., predictive maintenance or energy management) before scaling. 

Practical engineering implications

  • Polymer engineers and operations leaders in SMEs should prioritize pilot AI projects aligned with measurable KPIs to justify investments and build internal experience.
  • Collaboration with digital partners or industrial research consortia can reduce cost and expertise barriers.

Key Takeaways for Polymer Engineering Practice

  • Material Innovation: AI accelerates materials discovery, reduces time-to-performance validation, and supports sustainable alternatives.
  • Design & Selection: Data-driven tools enhance part design, material decisions, and early manufacturability assessment.
  • Processing: AI-augmented process controls and autonomous systems improve production stability, quality, and efficiency.
  • Recycling & Circularity: Intelligent sorting and integrated data frameworks enhance recyclate use and circular outcomes.
  • Strategic Competitive Advantage: AI is now foundational to operational excellence, innovation leadership, and resilience in the plastics sector.

Thanks for reading & #findoutaboutplastics

Greetings,

Herwig Juster





Literature:





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Thursday, 8 January 2026

Energy Consumption in Plastic Injection Molding: Hydraulic vs. Electric Machines (Rule of Thumb)

Hello and welcome to a new Rule of Thumb post (check out other Rule of Thumb posts here).

When it comes to plastic injection molding, energy efficiency is a key factor in both operational costs and sustainability. Let’s take a closer look at how different machine types compare:

If we set the energy consumption of traditional hydraulic injection molding machines with constant pumps as the baseline (100%), machines equipped with servo pumps already offer a significant improvement, consuming only about 54–55% of the energy. All-electric injection molding machines go even further, using just 48–49% of the energy compared to standard hydraulics.

However, machine selection should always be based on your specific production needs. In some cases, the part you want to mold may be better suited to a hydraulic machine with a servo pump, making this a perfectly valid choice despite the slightly higher energy usage.

In summary, while electric machines lead in energy efficiency, the best solution is always the one that fits your application requirements.

Figure 1: Energy consumption of hydraulic vs electric injection molding machines.

Literature: 

[1] https://www.findoutaboutplastics.com/2023/01/major-benefits-of-plastics-for.html


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Wednesday, 7 January 2026

5 Common Mistakes to Avoid When Selecting Polymers for Electric & Electronics Applications

Hello and welcome to a new post. In today’s post, we discuss five common mistakes to avoid when selecting polymers for electric and electronics applications such as connector housings.

Proper polymer material selection is the most effective antidote for battling plastic part failure and my aim is to help the plastics community to increase their confidence in material selection, especially with high performance polymers and recycling plastics. 

Avoid these 5 common mistakes when selecting polymers for electric and electronics applications

1️⃣ Ignoring Electrical Properties

-Failing to check dielectric strength, insulation resistance, and tracking resistance (CTI) can lead to electrical failures or safety hazards.

2️⃣ Overlooking Flame Retardancy Requirements

-Not verifying compliance with standards like UL 94 V-0 can result in non-compliant products and increased fire risk.

3️⃣ Neglecting Chemical and Environmental Resistance

-Forgetting to assess resistance to chemicals, moisture, and environmental stress can cause premature degradation, corrosion, or loss of performance.

4️⃣ Disregarding Dimensional Stability and Creep

-Choosing materials that warp, shrink, or deform under heat or load may compromise connector fit, function, and reliability over time.

5️⃣Underestimating Processability and Manufacturability

-Selecting polymers that are difficult to mold, have poor flow, or are incompatible with existing tooling can lead to defects, higher scrap rates, and increased production costs.

Figure 1: 5 common mistakes to avoid when selecting plastics for electrical applications.

Literature: 

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

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Monday, 5 January 2026

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

Hello and welcome to the Part 2C of our High Performance Thermoplastics selection blog series. Today we discuss the Ether-Ketone Polymer family (PAEK and PEEK), 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)

3. Key properties and design data for selection

4. Polymer Material Selection 4-stage funnel methodology (POMS-Funnel-Method)

5. Examples for Ultra- and high performance polymer selection

1. Introduction to Polyaryletherketones

Screening the patent literate regarding the invention of Polyaryletherketones, it was reported independently by Imperial Chemical Industries (ICI) and DuPont. Polyetheretherketone (PEEK) was first produced in 1978 by scientists at ICI in the UK, with the first batch made on November 19, 1978, by John B. Rose and Philip A. Staniland's team. ICI commercialized it as Victrex PEEK in the early 1980s, initially for demanding defense and aerospace uses, becoming a high-performance thermoplastic known for its strength, temperature resistance, and chemical inertness. 

In general, the aromatic ether ketone polymer family, including Polyetheretherketone (PEEK), Polyaryletherketone (PAEK), and Polyetherketoneketone (PEKK) are high-performance thermoplastics valued for their outstanding mechanical, thermal, and chemical properties. Recent research and industry trends are increasingly focusing on PAEK blends to further tailor and enhance performance for demanding applications.

2. Chemistry and Production

  • Chemical Structure:
    All three are aromatic polyketones with ether and ketone groups.

    • PEEK: Regular ether/ketone sequence.
    • PAEK: Family with variable ether/ketone ratios, allowing for property tuning.
    • PEKK: Higher ketone content, affecting crystallinity and processing.

  • PEEK Polycondensation Process:

    • Mechanism: PEEK is produced via a high-temperature polycondensation reaction, typically through nucleophilic aromatic substitution.
    • Monomers: The main industrial method (patented by Victrex PLC in the late 1970s) uses 4,4'-difluorobenzophenone (or 4,4'-dichlorobenzophenone) and hydroquinone (1,4-benzenediol or bisphenol).
    • Solvent & Catalysts: The reaction occurs in a high-boiling polar aprotic solvent, diphenyl sulfone (DPS), with a mixture of potassium and sodium carbonate as the base.
    • Process Steps:
      • Salt Formation: Hydroquinone reacts with alkali metal carbonates to form a bisphenate salt, releasing water and CO₂.
      • Polycondensation: The bisphenate salt reacts with 4,4'-difluorobenzophenone, displacing fluorine atoms and forming ether linkages, with potassium and sodium fluoride as byproducts.
      • Purification: The resulting high-molecular-weight PEEK powder is cooled, crushed, and washed with hot water and organic solvents (e.g., acetone) to remove residual salts and solvent.
      • Drying: The purified polymer is dried, often under vacuum at ~120°C.

  • PAEK Blends:

    • Produced by blending PAEK with other polymers or additives to achieve specific property profiles, such as improved toughness, flexibility, or processability.
3. Properties

The ether/ketone ratio impacts the thermal transitions of ether-ketone polymers. Table 1 illustrates the influence of the ether/ketone ratio on the thermal transitions of various Polyaryletherketones. As the ether/ketone ratio increases from 1.0 to 3.0, both the glass transition temperature (Tg) and the melting temperature (Tm) of the polymers decrease. Specifically, PEK (ether/ketone ratio 1.0) exhibits the highest Tg and Tm, while PEEEK (ratio 3.0) shows the lowest values. This trend demonstrates that increasing the ether content in the polymer backbone reduces the thermal transitions of Polyaryletherketones by enhancing chain flexibility and increasing the free volume between polymer chains.

For anyone working with high-performance materials, understanding these trends is key to selecting the optimal polymer for demanding applications. 

Table 1: Aromatic Ether-Ketone Polymers - influence of the ether/ketone ration on thermal transitions.

  • PEEK has high thermal stability (max. continuous use temperature UL746B = 260°C; max short-term use temperature: 310°C;  HDT 1.8 MPa = 160°C; melting temperature = 340°C), mechanical strength (tensile modulus = 4000 MPa; tensile strength = 110 MPa), inherent flame retardant (UL94 V0), and high chemical resistance.
  • By adding 30wt% glass fibers, the short term temperature performance of PEEK can be improved from HDT 1.8 MPa = 160°C to HDT 1.8 MPa = 230°C.
  • Blends:
    • Blending ketone-polymers with other polymers (e.g., polyetherimide, polyphenylene sulfide, liquid crystal polymers, or elastomers) can improve processability, impact strength, and tailor crystallinity.
    • Nanofiller or fiber-reinforced PAEK blends offer enhanced mechanical, thermal, and tribological properties.
  • PEKK has a slower crystallization rate which makes it good for 3D printing.
4. Processing Methods
  • Injection Molding, Extrusion, Compression Molding, Machining, 3D Printing.
  • PAEK Blends:
    • Improved processability and lower processing temperatures compared to pure PAEK.
    • Blends can be tailored for compatibility with specific manufacturing techniques.
  • Recycling of PEEK: Regrind of spure, gates and faulty parts can be used without problem up to a level of 25%. Important is to blend the regrind with virgin PEEK pellets to ensure uniform processing and use consistent amount of regrind. 
5. Applications
  • Aerospace: PEEK was originally developed for the aerospace industry. Its high strength-to-weight ratio, flame retardancy (meeting FST standards), and resistance to aerospace fluids like jet fuel are highly valued for improving fuel efficiency and safety: 
    • Structural components: Lightweight brackets, clamps, and clips can replace heavier aluminum parts without compromising strength.
    • Engine components: Seals, bearings, and insulation in turbine systems that withstand high temperatures and pressures.
    • Interior components: Used in seat frames and cabin panels due to its flame-retardant properties and durability.
    • Electrical insulation: Cable insulation and various electrical connectors due to its high dielectric strength. 
  • Automotive: 
    • Engine & Transmission: Thrust washers, seal rings, bushings, and gears in transmission and engine systems, where they endure high temperatures and mechanical stress.
    • Braking Systems: Components in ABS/ESC brake systems and brake wear sensors.
    • Fuel Systems: Seals, O-rings, and valve seats in fuel injection systems and pumps, due to resistance to various fuels and oils.
    • Traction motors: magnet wire coating by using direct extrusion on copper wire. 
  • Electronics
  • Medical: Surgical equipment and long-term implantable devices, because of its biocompatibility, radiolucency (transparent to X-rays), and ability to withstand repeated sterilization. Applications include handles for reusable surgical instruments, sterilization trays, and components in fluid transfer systems and pumps (e.g., in dialysis equipment). 
  • Oil & Gas: In the demanding high-pressure, high-temperature (HPHT) and corrosive environments of the oil and gas industry, PEEK's resistance to hydrocarbons, steam, and aggressive chemicals is crucial. Applications include sealing systems, downhole tools, Valve and Pump Components.
  • 3D Printing.
  • PAEK Blends:
    • Used where a balance of toughness, chemical resistance, and processability is required.
    • Fiber- or nanoparticle-reinforced blends are ideal for lightweight, high-strength parts in aerospace and automotive sectors.
6. Economic Aspects
  • Cost:
    High compared to engineering and other high-performance polymers, however blends can sometimes reduce costs by enabling easier processing or using less expensive co-polymers.
  • Value:
    Blends offer tailored solutions, potentially reducing total cost of ownership through improved performance and manufacturability.
7. Suppliers
  • PEEK: Victrex (VICTREX 450G™), Syensqo (KetaSpire®), Evonik (VESTAKEEP®),  Zhejiang Pfluon Chemical (PFLUON®), Zhongyan Polymer Materials Co (ZYPEEK).
  • PAEK: Victrex (LMPAEK™), Syensqo (AvaSpire® PAEK).
  • PEKK: Arkema (Kepstan®), Syensqo (APC and Cypek).
  • Ether/Ketone Blends: Offered by major suppliers and custom compounders; specific formulations may be proprietary.

Key Takeaway:
Ether ketone polymers represent a versatile and growing area in high-performance polymers, enabling engineers to fine-tune properties for specific application needs—especially where a balance of toughness, processability, and chemical resistance is critical.

In the next part, we will discuss Liquid Crystal Polymers (LCP) and High-performance Polyesters (Polycyclohexylene terephthalate - PCT).

Literature: 

[1] https://pmc.ncbi.nlm.nih.gov/articles/PMC10575340/#polymers-15-03943-f004

[2] https://www.vink-kunststoffe.de/produkte/peek/technisches-datenblatt-peek.pdf

[3] https://link.springer.com/chapter/10.1007/978-94-011-7073-4_18

[4] https://www.syensqo.com/en/brands/ketaspire-peek

[5] https://www.victrex.com/en/products/polymers/peek-polymers

[6] https://www.findoutaboutplastics.com/2020/11/plastic-part-failure-part-2-antidote.html


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