Wednesday, 1 April 2026

The 11 Functional Groups of Polymers — A Primer for Polymer Engineers

Hello and welcome to this new blog post in which we discuss the functional groups of polymers. 

Introduction — why functional groups matter

Figure 1: Overview of the 11 functional groups of polymers. 

Functional groups are the recurring atom clusters in organic molecules whose chemistry largely determines material properties (polarity, hydrogen-bonding, thermal stability, chemical resistance, chain rigidity, degradability, etc.). 

In polymers, the functional group(s) present in the backbone or pendant positions control bulk properties and processing behaviour, so identifying the dominant functional group is a quick route to predicting performance during material selection

What are the 11 functional groups we will discuss in this post:

  • Imide group
  • Sulfone Group
  • Amide Group
  • Ester Group
  • Ketone Group
  • Sulfide Group
  • Ether Group
  • Arene Group
  • Alcohol Group
  • Alkane Group
  • Haloalkane Group
Let us get starting!

1) Imide group — structure: –CO–N–CO– (cyclic or linear imide)
Figure 1: Functional groups of polymers: Imide group.

What it gives: outstanding high-temperature stability, good chemical resistance, high glass transition (rigid backbone), low creep.
Typical polymers / examples: Polyimides (e.g., Kapton®, Vespel®) used for high-T films, electrical insulation, aerospace parts. Polyimides are classic high-performance plastics made from dianhydride + diamine routes. 
Notes: Alkyl groups (R-) are saturated, non-aromatic hydrocarbon chains derived from alkanes (e.g., methyl, ethyl).
Aryl groups (Ar-) are aromatic rings derived from compounds like benzene.

2) Sulfone group — structure: –SO2– (often between aryl groups)
Figure 2: Functional groups of polymers: Sulfone group.

What it gives: high thermal stability, hydrolytic stability, rigidity and flame resistance; good dimensional stability and toughness in amorphous engineering resins.
Typical polymers / examples: Polysulfones / Polyethersulfones / Polyphenylsulfone (PSU, PES/PESU, PPSU — trade names include Ultrason®, Radel®). Widely used in medical devices, plumbing/valves, electrical components and under-the-bonnet automotive parts. 

3) Amide group — structure: –CONH–
Figure 3: Functional groups of polymers: Amide group.

What it gives: strong intermolecular hydrogen bonding resulting in high strength and toughness, relatively high melting point, moisture uptake (hydrophilicity increases with amide density), good abrasion resistance.
Typical polymers / examples: Polyamides (Nylons) — PA6, PA66, PA11, PA12; Semi-aromatic polyamides such as PPA, and fully-aromatic polyamides (aramids) such as Kevlar® for ballistic & high-strength uses. Use in fibers, gears, bearings, structural components. 

4) Ester group — structure: –COO– (ester linkage in backbone)
Figure 4: Functional groups of polymers: Ester group.

What it gives: backbone polarity (good mechanical strength), susceptibility to hydrolysis (hence biodegradability for some), good melt processability (thermoplastic polyesters).
Typical polymers / examples: Polyesters — PET (polyethylene terephthalate), PBT, PLA (polylactide). Used for fibers, bottles, films, engineering thermoplastics and (for some aliphatic esters) biodegradable medical devices. 

5) Ketone group — structure: –CO– (ketone carbonyl in backbone or adjacent to aromatic units)
Figure 5: Functional groups of polymers: Ketone group.

What it gives: increased backbone polarity and stiffness; when combined with ether linkages in high-performance families it confers elevated Tg and chemical resistance.
Typical polymers / examples: Poly(aryl ether ketone) family (PAEK) — includes PEEK, PEK, PEKK — used for high-temperature structural parts, bearings, medical implants, and additive manufacturing in demanding applications. PAEKs combine aryl, ether and ketone functionalities giving excellent thermo-oxidative stability. 

6) Sulfide group — structure: –S– (or disulfide –S–S– / polysulfide –Sx–)
Figure 6: Functional groups of polymers: Sulfide group.


What it gives: enhanced temperature resistance, chemical and solvent resistance; excellent flow for injection molding; inherent flame retardant properties; excellent dimensional stability; 
Typical polymers / examples: Polyphenylene sulfide (PPS) trade names include Ryton®, Fortron®.

7) Ether group — structure: –O– (alkyl or aryl ether linkages)
Figure 7: Functional groups of polymers: Ether group.

What it gives: flexibility (aliphatic ethers), good low-temperature toughness, and for aromatic ether linkages (polyarylethers) increased thermal stability and oxidative resistance. Ethers reduce crystallinity when in backbone and improve chain mobility.
Typical polymers / examples: Polyethers (polyethylene glycol PEG/PEO; polypropylene oxide PPO), polyetherimide (PEI), polyethersulfone (PES), epoxy networks (contain ether linkages after cure). Applications span elastomers, polyurethanes (polyether polyols), and engineering plastics. Trade names include Noryl® PPE, Ultem® PEI, Veradel® PESU.

8) Arene (aromatic ring) group — structure: –Ar– (phenyl, substituted phenyl rings in backbone or pendant)
Figure 8: Functional groups of polymers: Arene group.

What it gives: backbone rigidity (high modulus), thermal stability, UV interaction (often poor UV resistance unless stabilized), pi-stacking that influences mechanical and barrier properties. Aromatic content generally increases glass transition and heat resistance.
Typical polymers / examples: Polystyrene (PS) — aromatic pendant phenyls on a saturated backbone; poly(phenylene), polyaryls and many high-performance polymers with aromatic repeat units (e.g., polyimides, PAEK family). Polystyrene is a major commodity aromatic polymer used for foams, rigid packaging and consumer products. 

9) Alcohol (hydroxyl) group — structure: –OH (pendant or chain-end hydroxyls)
Figure 9: Functional groups of polymers: Alcohol group.

What it gives: hydrogen bonding, polarity, water solubility (if dense), reactivity for crosslinking (e.g., with isocyanates to form polyurethanes) or functional modification. Hydroxyls raise surface energy and adhesion.
Typical polymers / examples: Polyvinyl alcohol (PVA, PVOH) — water-soluble, used in films, adhesives and hydrogels; alcohol endgroups in polyols (polyether or polyester polyols) are core building blocks for polyurethanes. 

10) Alkane group (saturated hydrocarbon backbone) — structure: –CH2–CH2– etc. (non-functional hydrocarbon chain)
Figure 10: Functional groups of polymers: Alkane group.

What it gives: low polarity results in low surface energy, excellent chemical resistance to polar solvents, high flexibility (especially in low Tg aliphatic polyolefins), good electrical insulating properties and very high production volumes (commodity plastics).
Typical polymers / examples: Polyethylene (PE), Polypropylene (PP). These are the polyolefin family used for films, containers, piping, and fibers. Expect low density, good toughness, and simple processing. 

11) Haloalkane group (alkyl halide pendant or backbone) — structure: –C–X (X = Cl, Br, F)
Figure 11: Functional groups of polymers: Haloalkane group.

What it gives: increased flame retardance (e.g., chlorinated polymers), increased polarity and density, and ready sites for nucleophilic substitution or further modification; halogens can also raise refractive index and change dielectric properties.
Typical polymers / examples: Polyvinyl chloride (PVC) — chlorine on backbone carbons; fluoropolymers (e.g., PTFE — where fluorine dominates) are extreme cases with outstanding chemical resistance and low friction. PVC is used in construction, pipes, cable insulation and flooring; fluoropolymers are used where chemical inertness and high T performance are needed. 

Mixed-functionality polymers & location of the group
  • Backbone vs pendant vs endgroup: a functional group in the backbone (repeat unit) typically dominates bulk mechanical/thermal behaviour. Pendant groups (e.g., the phenyl in polystyrene or the chloro in PVC) tune Tg, polarity and solubility. Endgroups mainly affect surface chemistry and reactivity. 
  • Combinations are common: many engineering polymers combine functional groups (for example, PAEKs include arene, ether and ketone motifs; polysulfones include aryl, ether and sulfone units), which gives the unique combined property sets. 
Overview of all the 11 functional groups of polymers

Figure 12: Overview of the functional groups of polymers.

Check out my video on functional groups too: 


Monday, 23 March 2026

ISO 1043 / ISO 11469 Plastic Part Marking Code Example - Metal fillers, Elastomers, or special Fillers (MEF)

Hello an welcome to a new blog post. In plastic part design, proper material selection and processability are essential considerations. Additionally, part marking plays a crucial role, as it enables more efficient sorting and recycling of plastic components. The two primary standards governing part marking are ISO 1043 and ISO 11469.

Example >PARA-(CF+MEF(x))<

Based on ISO 1043 (specifically ISO 1043-1 regarding plastics symbols), the notation >PARA-(CF+MEF(x))< is a part marking code used to identify the material composition of a molded plastic component made out of PolyarylAmide (PARA; PA-MXD6). 

Figure 1: Plastic part marking example with focus on special additives. 

Here is the breakdown of that marking:

PARA: PolyArylAmide (PA-MXD6) - the base polymer.

CF: Carbon Fiber

MEF: This indicates a specific, likely proprietary, modification or additive blend. In the context of this material, it refers to special filler package, potentially containing Metal fillers, Elastomers, or special Fillers (MEF) which are used to enable EMI-shielding.

(x): Often followed by a number (e.g., in a technical data sheet, it might appear as >PARA-MEF(1)7<, this indicates the specific grade or a percentage/variant within the supplier's internal classification system.

> <: The angled brackets indicate that the part is marked in accordance with ISO 11469 for identification and recycling, as required for parts over a certain weight. ISO 11469 does not define a universal minimum weight for marking; however, industry standards (e.g., in automotive) generally require marking for parts weighing more than 100 grams. Smaller components, often those under 25 grams or with a surface area smaller than, are usually exempt from this marking requirement. 

Check out my other part marking posts too: 

Plastic Part Marking – Overview Codes and Standards (incl. miniguide for downloading)

Thanks for reading and #findoutaboutplastics

Greetings, 

Herwig 



Literature:

[1] https://www.findoutaboutplastics.com/2020/12/plastic-part-marking-overview-codes-and.html

[2] https://rsjtechnical.com/dqr/rules/code161/

Wednesday, 11 March 2026

Plastic Part Failure Analysis - Example Recycled PP Pallet Corner Cracking in Cold Warehouse

Hello and welcome to this plastic failure analysis post. Apart from polymer material selection, and preventing plastic part failure, I focus in my role as certified plastics expert witness to support the polymer engineering community in solving failed plastic part cases. 

Example recycled PP pallet corner cracking in cold warehouse

Overview on the situation

  • Part / material: Pallet (EUR/EPAL-Palett; 800 mm × 1.200 mm × 144 mm) made out of mechanically recycled polypropylene (rPP). 
  • What happened and which failure was observed (Figure 1): Corner cracks and brittle fracture of corner area after it was dropped at low temperature (below 10°C).

Figure 1: Example plastic failure analysis - broken corner of a palett made out of recycled PP. 

Plastic part failure analysis

Figure 2 shows the steps of a general plastic part failure analysis protocol [1] which can be followed to obtain a solid root cause and take corrective actions to prevent failure in the future. In this post I focus on the steps "material analysis, determination of failure mode and cause, and corrective actions". 

Figure 2: Overview of the steps for performing a plastic part failure analysis. 

Root cause analysis and results:

  • Identification of material by using Differential Scanning Calorimetry (DSC): 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.

Pellets and pallet sections were both analyzed with DSC and in both, pellets and pallet sections Polypropylene could be identified via the melt peak at 170°C (Figure 3). Apart from PP, Polyethylene (LDPE and HDPE) melting peaks could be identified and it is not unusual for recycled PP to contain LDPE and HDPE too. They are referred to as mixed polyolefins and use packaging and industrial waste as primary recycling source. Packaging waste contains often PS and PET too, which could not be found in our material samples. Also, three other polymers could be identified, which may come from the industrial waste stream: Polyoxymethylene (POM), Polyamide 6 (PA 6), and Polytetrafluorethylene (PTFE with the two transitions at 23°C and 340°C). Having altogether five polymers in a PP base polymer system has impact on the material and final part properties. 

Figure 3: DSC result of pellets and pallet - apart from PP, five other polymers were found. 

  • Property variability: Contamination with LDPE/HDPE/POM/PA 6/PTFE, and unknown additives lead to a variability in mechanical and thermal properties. Also, differences in melt viscosity (via MFR) could be shown. 
  • Degradation: Oxidative degradation from multiple heat histories due to processing resulted in a lower molecular weight and reduced toughness.
  • Impact modification: Insufficient impact modification for low-temperature use.
  • Part design and processing: Poor weld line strength due to contamination and poor flow during filling phase in injection molding.

Corrective action proposals

To address and prevent plastic part failure in the future, the following corrective measures should be considered:

  • Improve feedstock control: Implementation of tighter incoming quality checks, including MFR, DSC, ash content, and FTIR screening to detect contamination.
  • Add stabilization: Usage of a combination of hindered phenolic and phosphite antioxidants, keeping in mind any odor constraints.
  • Enhance impact resistance: Incorporation of impact modifiers (such as EPR/EPDM) and/or blend with virgin PP to maintain stable performance.
  • Optimize processing: Lower shear rates, reduce residence time, and improve venting and filtration (e.g., use of melt filters) during processing.

Prevention tips for part failure:

To enhance part reliability and prevent failures, the following best practices should be considered:

  • Design considerations: Account for the variability of recycled materials by incorporating optimized corners and radii, and by avoiding thin snap features in your designs.
  • Quality assurance: Implement lot-based mechanical testing, such as notched Izod or Charpy impact tests at the intended service temperature, to ensure consistent performance.

Applying these measures will help improve the durability and quality of our products.

If the application is cold-impact critical, rPP should only for non-critical components considered or require certified PCR grades.

Other examples from my case directory:

When Childhood Crumbles: Understanding Plastic Part Failure in LEGO® Bricks

Curious how I can best support you with your plastics challenges? 

Take my quick 6-question Case Viability & Expert Fit Scorecard!

By completing this short assessment, you’ll receive a personalized score that helps determine the most effective way I can assist you. 

Take the Case Viability & Expert Fit Scorecard

or contact me here directly. 

Thanks for reading & #findoutaboutplastics

Greetings, 

Herwig

Literature: 

[1] Jeffrey A. Jansen: Characterization of Plastics in Failure Analysis, Stork Technimet Inc / The Madison Group

[2] http://www.justerexpertwitness.com

[3] https://youtu.be/7P5AG5hkJao

[4] https://www.justerexpertwitness.com/case-directory

[5] Ehrenstein G, Riedel G, Trawiel P, Thermal Analysis of Plastics, Carl Hanser Verlag, Munich, 2004


Thursday, 5 March 2026

First-Principal Thinking in Polymer Engineering I A Powerful Tool covering innovation till problem solving I Rule of Thumb

Hello and welcome to this new blog post! 

First-principles thinking is a powerful problem-solving approach where you break down complex problems into their most basic, fundamental elements and then reassemble solutions from the ground up. It is part of one of my 20 mental models I use for effective thinking in polymer engineering. 

Mr. Michael Sepe, with his extraordinary contributions to the plastics industry as a teacher, expert, and consultant, was a strong believer in first principles thinking (Quote reported by Jeff J. :“the fundamentals don’t change” [1]).  By reading Michaels articles and books, I have learned a lot about polymer engineering and also the first-principles approach, which I would like to share with you in this post to keep the spirit of Michael among us!

How to apply First-principles thinking for your plastics challenges?

Instead of relying on analogies or established methods, you ask: “What do we know for sure?” and “What is truly essential?”

Here are some examples of first-principles thinking in polymer engineering and the plastics industry:

1. First principles approach on Understanding Material Performance

The performance of plastic materials is fundamentally determined by their structure. The polymer structure is defined by its molecular architecture, which directly affects key properties such as polarity, crystallinity, and viscoelasticity.

Molecular architecture can be divided into:

  • Molecular construction (including functional groups, branching, and tacticity)
    • Functional groups influence the polarity of the polymer.
    • Tacticity affects the crystallinity of the polymer.

  • Molecular weight (including molecular weight distribution)
    • Molecular weight distribution impacts the viscoelastic behavior of the material.

A plastic compound is composed of a base polymer and various additives. The characteristics of the base polymer are primarily determined by its molecular structure.

The final plastic compound defines the material’s mechanical, thermal, chemical, and environmental properties.  As a practical implication for polymer selection and design, you can pick the functional group for your target property: e.g., if you need high-temperature structural parts, aim for imide/sulfone/aryl ketone chemistries.

Figure 1 summarizes the first-principles approach on understanding plastic material performance. 

Figure 1: first-principles approach for understanding plastic material performance. 

2. Designing a New Polymer for a Specific Application

Traditional approach: Use existing polymers and modify them to fit the application. 

First-principles approach:

  • Start by asking: What are the fundamental properties required (e.g., thermal stability, flexibility, chemical resistance)?
  • Analyze the molecular structure-property relationships.
  • Design a polymer backbone and side groups from scratch to achieve the desired properties, rather than tweaking existing materials.
3. Reducing Plastic Waste

Traditional approach: Improve recycling rates using current technologies. 

First-principles approach:

  • Ask: What makes plastics hard to recycle? (e.g., immiscibility, additives, contamination)
  • Break down the recycling problem to its chemical and physical fundamentals.
  • Develop new polymers that are inherently easier to depolymerize or upcycle, or invent additives that enable closed-loop recycling.
4. Improving Barrier Properties in Packaging

Traditional approach: Add more layers or coatings to existing films. 

First-principles approach:

  • Ask: What fundamentally limits gas or moisture permeability?
  • Investigate the molecular interactions and free volume in the polymer matrix.
  • Engineer the polymer structure or blend with nanomaterials to minimize permeability at the molecular level, rather than just adding layers.
5. Coloring Polymers

Traditional approach: Use standard masterbatches and pigments. 

First-principles approach:

  • Ask: What causes color fading or poor dispersion?
  • Analyze the interaction between pigment molecules and polymer chains.
  • Design new pigment chemistries or surface treatments that bond better with the polymer, ensuring long-lasting and uniform color.
6. Lightweighting Automotive Parts

Traditional approach: Use existing glass-fiber reinforced polymers. 

First-principles approach:

  • Ask: What is the minimum material and structure needed for required strength and safety?
  • Use computational modeling to design new composite architectures or hybrid materials from the molecular level up, achieving strength with less material.
7. Developing Biodegradable Plastics

Traditional approach: Use known biodegradable polymers like PLA or PHA. 

First-principles approach:

  • Ask: What chemical bonds are most susceptible to environmental degradation?
  • Design new polymer structures with targeted weak links that break down under specific conditions, ensuring both performance and biodegradability.

In summary:

First-principles thinking in polymer engineering means questioning every assumption, understanding the science at the most basic level, and building innovative solutions from the ground up. It’s a mindset that can lead to breakthroughs in materials design, sustainability, and manufacturing.

For further reading, I recommend my mental models post which can be found here:

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

Thanks for reading & #findoutaboutplastics

Greetings, 

Herwig



Literature:

[1] https://www.linkedin.com/posts/jeffrey-jansen_plastics-education-scholarship-activity-7224029479042482176-0wcT

[2] https://give.4spe.org/campaign/michael-p-sepe-memorial-scholarship/c604608

[3] https://www.findoutaboutplastics.com/2026/01/20-mental-models-for-effective-thinking.html

Sunday, 22 February 2026

Don Polimero & The Plastics Pellets Band - "Plastics are the solution and not the problem"

Hello and welcome to a new blog post.


๐ŸŽถ Today I tried out the new Gemini Music feature, using the fast modus and created a 30s song.

1️⃣ First I created the artist Don Polimero as a picture. He is singing about plastics and that they are part of the solution and not the problem.

2️⃣ Then uploaded the picture to Gemini, create music and selected "Folklore" style and voilร  the song is ready.

๐Ÿ‘‡ Check it out below & give it a try for yourself.


And here is the 2nd verse with recycling and sustainability as main topic:

Thanks for listening and reading & #findoutaboutplastics

Greetings,

Herwig Juster



Monday, 16 February 2026

๐Ÿ“š 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


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

  • High density plastics: 
    • can be used as counter weights / balancing weights
    • locally integrated in plastic part where it is needed via 2-component injection molding

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 EPDMNBR 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/

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