PLASTIC MATERIAL PROPERTIES & SELECTION PROCESS

Course Introduction

Plastic parts range from simple devices to complicated test equipment and implants. Plastics in engineering are used more and more for weight, cost, and performance purposes. This workshop will discuss plastics used in the injection molding process for medical, automotive and audio industries. The first section will review the general composition of plastic materials which will include the materials added to the basic polymers. The second section will discuss many factors that contribute to the plastic selection. The final section will review the chemistry and the application of most common plastic materials.

Course objective

Polymer properties
Polymer additives & modifiers
Material selection process
Common polymers & their physical, thermal & chemical properties
Plastic injection molding do’s & dont’s
Common polymer issues faced at your workplace and a systematic way to resolve them

Course Content

1) Introduction to polymers (thermoplastic and thermosets)

1. Linear, Branched, Cross-linked Polymers
2. Isomers
3. Molecular Weight

2) Additives

1. Fillers
2. Impact Modifiers and Tougheners
3. Radiation Stabilizers
4. Pigments, Extenders, Dyes, Mica
5. Thermal Stabilizers & Antistats
6. BaSo4

3) Material selection process

i. Physical and Mechanical Properties

- - Fatigue
  - Wear resistance
  - COF (Coefficient of friction)
  - Shrinkage
  - Moisture absorption
  - Strength
  - UV resistance

ii. Flammability

iii. Thermal Properties

- - CUT temperature
  - ARO temperature

iv. Electrical Properties

v. Chemical Resistance

vi. Sterilization Capability

vii. Long-Term Durability

viii. Leachables and Extractables

ix. Shelf Life and Aging

x. Joining and Welding

xi. Medical Grade Plastics

xii. Food grade Plastics

4) Common polymers & their physical, thermal & chemical properties

i. The 4 documents that we must have from every polymer raw material supplier

1. 1. Material properties data sheet
  2. Material processing data sheet
  3. Material design guidelines
  4. MSDS

ii. Semi-crystalline resin

1. 1. PP
  2. PE
  3. POM
  4. PBT
  5. PPS
  6. PEEK
  7. PFA, PVDF
  8. PA

iii. Amorphous resin

1. 1. PS
  2. PMMA
  3. PC
  4. PVC
  5. ABS
  6. PPE
  7. PSU, PES

iv. Polyurethane (PUR)

v. Fluorinated Ethylene-Propylene (FEP).

vi. Methacrylate Acrylonitrile Butadiene Styrene (MABS)

vii. Measurements of the resin

1. 1. melt flow index
  2. density
  3. molecular weight distribution
  4. melting point, softening point

viii. Measurements of the converted articles

1. 1. dimensional stability
  2. shrinkage
  3. warpage
  4. stressed-crack
  5. surface tackiness

ix. How to measure and quantify shrinkage and warpage?

x. Common injection molding problems and troubleshooting

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