Due to the versatility, durability, and ease of use of thermoplastics, they have become a cornerstone in modern manufacturing and design. It is no wonder that builders use thermoplastics in a wide range of applications, from specialty seals for automotive products to everyday consumer tools. Still, considering the variety of alternative building materials like metals and plastics, a common question is, “How do you determine when to use thermoplastic components?” Real Seal answers below.
When to Use Thermoplastic Components
Thermoplastics are re-meltable, recyclable, durable, chemically resistant, strong, environmentally friendly plastic materials. They are a form of plastic polymer that becomes pliable or moldable at a high temperature and solidifies when cold. The common types of thermoplastics include:
- Polyethylene (PE) is used in packaging, containers, and piping.
- Polypropylene (PP) is used in automotive components, textiles, and household items.
- Polycarbonate (PC) is known for its resistance and is used in eyewear and electronic housings.
- Acrylic (PMMA) is used in lighting fixtures and displays.
- Nylon (PA) is frequently used in gears, bearings, and textiles.
When determining if thermoplastic would be better than its alternatives, some precautions need to be taken. Consider the following when choosing between thermoplastic or another type of material.
Lightweight Requirements
When there is a need to reduce weight, thermoplastic may be the perfect solution compared to metals and ceramics, which are significantly heavier. Industries like aerospace and automotive need lightweight materials to improve fuel efficiency and performance.
In the automotive. industry, manufacturers use thermoplastics in bumpers, dashboards, and interior panels to reduce the weight of the vehicles. The reduced vehicle weight, in turn, makes the car function more safely.
High Volume Production
For components for consumer electronics, toys, or packaging, thermoplastics are an ideal, cost-effective solution with consistent quality. Having consistent quality is essential for bulk productions when items should be uniform.
Flexibility and Design Freedom
If you need design flexibility, they are the ideal material for your product. You can mold thermoplastics into intricate shapes, allowing manufacturers to create components with fine details or integrated functionalities. This property makes thermoplastics ideal for medical devices requiring intricate designs and electronic casings with precision cutouts for ports and buttons.
Resistance to Impact and Wear
Some thermoplastics like polycarbonate and nylon can withstand impact, harsh conditions, and frequent use. This makes them ideal for protective gear—like helmets, shields, and safety goggles—and for mechanical parts—like gears, bearings, and housings in machinery.
Cost Efficiency
Often more comfortable than their ceramic and metal counterparts, especially when it comes to large-scale productions, they can also be reused and recycled. These features enhance their cost-effectiveness even more.
Environmental Considerations
The world’s growing concern for sustainability and the impact of plastics on the environment demands the reuse and efficient recycling of plastics. Countries around the globe are showing innovation and creativity in tackling the issue of plastic waste. Many are pushing for a circular economy that promotes the reuse of materials. The recyclability of thermoplastics makes them an attractive option. One can easily melt, reform, and reuse them in different applications such as green building materials, reusable containers, and automotive interiors.
Thermal and Chemical Resistance Needs
Some thermoplastics like polytetrafluoroethylene (PTFE) and polyetheretherketone (PEEK) are resistant to extreme temperatures and corrosive chemicals, making them suitable for:
- Industrial Piping
- Electrical Insulation
- Medical Implants
- Transparent Applications
In some products, optical clarity is important. This is where thermoplastics like acrylic and polycarbonate are ideal. They are used in:
- Tail lights and headlamp covers in automotive lighting
- Screens and signage in display panels
- Transparent partitions requiring high strength, such as those used in aquariums
Limitations of Thermoplastics
Although the versatility of thermoplastics makes them the perfect solution, they are still imperfect. This is due to the fact that they still have limitations. In extremely high temperatures and environments, thermosetting plastics or metals may be the better alternative. In addition, exposure to UV radiation or certain chemicals may cause degradation to some thermoplastics.
Explore How Thermoplastics Can Help You
The adaptability, durability, recyclability, and cost-effectiveness of thermoplastics are revolutionizing various industries. If you want to improve product design with lightweight materials, create high-performance specialty seals, or develop components using innovative materials like rubber polyurethane, thermoplastics may be the versatile solution that can meet your modern needs. If you are ready to find the perfect solution for your application, get in touch with our experts today, and we will be happy to help you bring your vision to life.
