Here are a few tips for choosing the correct Plastic materials for Your Prototyping

The availability of hundreds of different types of plastics on the market makes it challenging to choose the material that will serve your next rapid prototyping or low-volume manufacturing project in the most effective manner. When deciding the kind of plastic to employ, you must make compromises regarding cost, moldability, surface polish, durability, strength, and many others. The kind of plastic used is determined not only by the function of the component but also by the surroundings in which it performs that function.

Here are some of the most typical applications that our clients bring to us, along with the kind of plastic we suggest using for each one, so that you can better understand how various types of plastics are utilized.

Transparent components such as lenses, windows, and other parts

Which plastics are most suited for clear lenses, windows, and other transparent applications? Acrylic, commonly known as PMMA, is highly recommended by our team. When combined with plexiglass, this substance may create completely unbreakable windows. It is inexpensive, can be polished to a high sheen, and has muscular tensile strength. On the other hand, polycarbonate outperforms it in both impact and chemical resistance.

If you want something more robust, we suggest polycarbonate (PC) because it is more long-lasting and has outstanding optical characteristics, making it an ideal material for use in lenses, DVDs, and bulletproof windows. PC can be bent and molded at room temperature without breaking, making it a handy material for prototyping that does not need costly mold equipment. This is another one of PC’s beneficial characteristics. It is more costly than acrylic, and since it may produce potentially dangerous compounds when subjected to hot water for extended periods, it is not considered suitable for food preparation.

Mechanical Parts

Which types of plastic resins are ideal for use in the fabrication of mechanical parts? Nylon, also known as polyamide, is one of the resins used most often for the production of mechanical components (PA). It is often used in engine compartments as a suitable replacement for more straightforward metal components due to its high resistance to heat and vibration. Although nylon works well as a filament for 3D printing in plastic prototype service, over time, it will soak up water if exposed. It has a slick surface when molybdenum is added, but nylon-to-nylon gear trains are not a good idea. Plastics that are similar to one another tend to cling together, therefore it is preferable to alternate the kinds of plastic used.

Polyoxymethylene is yet another substance that comes highly recommended for use in mechanical components (POM). POM is a form of acetal resin used in Delrin production by DuPont. Delrin is an excellent plastic that may be used for gears, screws, wheels, and other types of mechanical components. Although rugged and sturdy, it is susceptible to deterioration when exposed to alkali, chlorine, or hot water. In addition, it isn’t easy to glue or attach acetal to other materials. It is often mixed with nylon when it comes to the construction of plastic gear trains.

Tools and Hardware

Which plastics hold up best under severe conditions, such as those in toolboxes and hardware? There are many different options available here. The sturdy casings for toolboxes and the bodies of power tools are often made out of high-impact polystyrene, also known as HIPS. Polystyrene is used for one-time use packaging because of its low cost, which is also one of the reasons why it is not regarded as ecologically friendly.

The material known as acrylonitrile butadiene styrene, or ABS, could be a superior option. ABS’s impact resistance is tremendous and highly robust, meaning that it is resistant to ripping and breaking. It is not only lightweight, but it is also capable of being significantly strengthened by the addition of glass fibers. It is often discovered in Lego bricks as well as keyboard keys.

Plastic Containers

What about containers made of cheap plastic that is produced in large quantities? In the food storage containers industry, polypropylene (PP) is the material of choice since it can withstand being washed in hot water without deteriorating, is resistant to oils and solvents, and does not leech chemicals, making it safe for use with food. The fact that it can be shaped easily into a living hinge, such as the kind that is often seen on the top of an aspirin bottle, is one of the many benefits that it offers. This particular form of joint may undergo repetitive bending without becoming damaged. Pipes and hoses are another everyday use for it.

Polyethylene, often known as PE, is the most widely used plastic, even though it does not have exceptionally high levels of strength, hardness, or rigidity. PE is a kind of plastic that is often milky white in color and may be found on items such as prescription bottles, milk and detergent bottles, and garbage cans. It has a low melting point while being exceptionally resistant to various chemicals. Because of its high degree of elasticity, it is also used in producing plastic bags and cling film.

Toys

What kind of plastic is recommended for use in the manufacture of toys for kids? Because it is affordable, non-toxic, and exceedingly colorfast, polyethylene (PE) produces about one-third of all plastic toys worldwide. Toys intended for use outside and in recreational settings that will be exposed to a significant amount of sunlight may benefit from adding additional UV stabilizers.Toys constructed from ABS or nylon have better impact resistance since they are more robust, stiffer, and durable.

Rubber

Which plastic polymers have the most significant characteristics in common with rubber? Injection molding of rubber-like resins is required for various applications because of the rubber’s soft and elastic qualities. In this instance, we use thermoplastic polyurethane, more often referred to as TPU. It is available in various specialized formulations, each of which aims to provide high elasticity, low-temperature performance, and long-term stability.

TPU is infamous for collecting moisture from the air, making it more challenging to manufacture than other plastics because of this property. TPU may be found in a wide variety of applications, including but not limited to power tools, caster wheels, cable insulation, and athletic goods. Because it is resistant to the effects of solvents, it is used in a variety of commercial settings.

The final option for over-molding is thermoplastic rubber, often known as TPR. This material is low-cost and straightforward, making it ideal for applications such as cushioned rubber grips.

Takeaway

Plastics come in a diverse spectrum of types, and the possible combinations of those types are much broader. At an early point in the design process, it is essential to specify the crucial criteria not just for your prototype but also for any future production components so that you may make an informed choice about the materials to use.

In light of these criteria, a suitable plastic may be selected among the various prototyping possibilities to provide the most accurate depiction possible of the final production units. Because of this, in the end, there will be less uncertainty and risk associated with the final product, but the pace of learning throughout the process of developing new products will speed up. If you are looking to plastic prototype manufacturers for your next project , please reach out to us !