1. What characteristics are most critical to the application?

Amorphous Thermoplastics
Conductive to thermoforming
Low chemical resistance
Transparent applications
Distort and soften over a
wide temperature range
Not suitable for bearing and
wear
Poor fatigue resistance
Conductive to bonding with
solvents and adhesives
Break down with extended
UV exposure unless
protective additives or
laminates are used
Potential Material Choices
ABS
Acrylic
Kydex
Noryl
PETG
Polycarbonate
Polystyrene (HIPS)
Polysulfone
PVC
Radel R
Ultem

2. What External and Environmental Factors Will the Product be Exposed To?
a. Temperature Range vs. Cost
Amorphous Thermoplastics
Highest to
Cost
Lowest
Ultem

Radel R

Polysulfone
Noryl
Polycarbonate
ABS
Polystyrene
(HIPS)
Kydex
PVC
PETG
Acrylic

b. High Traffic Areas (Impact Resistance)

Amorphous Thermoplastics
Izod Impact (notched)
Kydex
Polycarbonate
Radel R
ABS
Noryl
Polystyrene (HIPS)
PETG
Polysulfone
Ultem
PVC
Acrylic
c. Chemical Resistance

d. FDA Compliance (FDA compliant formulations can be made available in the following mater
Amorphous Thermoplastics
FDA compliance capable
Radel R
Acrylic
PETG
Polycarbonate
Polystyrene (HIPS)
Polysulfone
PVC

Ultem

6. Is the product a structural or cosmetic application? Is bending stiffness important?

Amorphous Thermoplastics
Flexural modulus
Plastic Material
stiffness (psi)
Ultem (30% glass)
1,300,000
Polycarbonate (20% glass)
800,000
PVC
481,000
Ultem
480,000
Acrylic
480,000
Polysulfone
390,000
Noryl
370,000
Radel R
350,000
Polycarbonate
345,000
Kydex
335,000
Polystyrene (HIPS)
310,000
PETG

310,000

ABS

304,000

Plastic Material

Advantages

Polystyrene
HIPS
(High Impact Polystyrene)

Clear plastic, very moldable,

inexpensive, recyclable, high
chemical resistance, high
electrical resistance, heat
distortion ~200F
Very moldable, relatively
inexpensive

Polyethylene (PE)

Chemically resistant, high

impact resistant, high
electrical resistance, fairly
economical, can be UV
protected with additive

Polypropylene (PP)

High level of stiffness, light

weight, high heat deflection,
chemical resistance at room
temperatures

ABS
(Acrylonitrile Butadiene
Styrene)

Engineered plastic that can

be customized to desired
levels of stiffness, hardness,
heat deflection, and many
other characteristics

PVC
(Polyvinyl Chloride)

Very high chemical

resistance, stain resistant,
stiffer than ABS, high room
temp. impact strength,
natural flame retardant
qualities

PVC/ABS (alloy)

PVC/Acrylic

Polycarbonate

Polycarbonate/ABS

Easy to process, very

cosmetic, dimensional
stability, impressions well off
a textured tool, maintains
tight dimensional tolerances,
retains some of PVCs natural
flame retardant qualities
Easy to process, highly
customizable alloy, high
impact resistance, very high
chemical and stain resistance
Extremely high impact
resistance, high clarity good
for transparent parts,
precision molding, good
insulator, high heat distortion
point ~270F
When compared to true
polycarbonate less
expensive, lower heat
distortion ~240F, much
easier to process, higher
chemical resistance

(thermoplastic olefin)

High impact strength (even at

cold temperatures), high
dimensional stability (low
mold shrinkage), stiffness,
high chemical resistance

PETG
(polyethyleneterephthalate)

Very easy to process, high

clarity good for transparent
parts

TPO

COMMODITY GRADE PLASTIC EXTRUSION MATERIALS

Acrylic (PMMA)
ABS
G.P. Polystyrene (GPPS)
High Impact Polystyrene (HIPS)
PVC Rigid and Flexible (clear and pigmented)
Polypropylene (PP)
Polyethylene (LDPE and HDPE)
PETG
SAN
Thermoplastic Elastomers (TPEs)
Thermoplastic Olefins (TPOs)

ENGINEERING GRADE PLASTIC EXTRUSION MATERIALS

Geloy (ASA)
Noryl (PPO)
Polycarbonate (PC)
Polysulfone (PSU)

application?
Thermoplastics
Difficult to thermoform
High chemical resistance
Opaque
Sharp heat distortion point
Good for bearing and wear
Good fatigue resistance
Resistant to bonding with
solvents and adhesives

Potential Material Choices

TPO
PET
Polypropylene
PPS
PTFE
UHMW-PE
HDPE
LDPE
Nylon
Acetal
PBT
PEEK

l the Product be Exposed To?

Temperature
Resistance
Radel R
Ultem

Polysulfone
Polycarbonate
Noryl
Acrylic
Polystyrene
(HIPS)
ABS
Kydex
PVC
PETG

Toughness
(ft-lbs/in)
18
12 16
13
7.7
3.5
2
1.7
1.3
1
1
0.4

Thermoplastics
High Chemical Resistance
LDPE
HDPE
UHMW-PE
Polypropylene
PTFE
PVDF
PEEK
PBT
Acetal
Nylon
PET
PPS

s can be made available in the following materials)

Semicrystalline Thermoplastics
FDA compliance capable
UHMW-PE
Polypropylene
PTFE
PVDF
PEEK
PBT
Acetal

Nylon
PET
HDPE
LDPE

ation? Is bending stiffness important?

Semicrystalline Thermoplastics
Flexural modulus
Plastic Material
stiffness (psi)
PPS
600,000
PEEK
590,000
Acetal
420,000
Nylon
410,000
PET
400,000
PBT
330,000
PVDF
310,000
Polypropylene
215,000
HDPE
200,000
UHMW-PE
110,000
PTFE
72,000
LDPE

Disadvantages

Industry Examples

Cracks and breaks easily

Marginal crack and break
resistance

Disposable cups, disposable

applications, decorative
applications, electrical
applications
Picture frames, shower walls,
food containers

High mold shrinkage not

suited for tight dimensional
tolerances, cosmetic
deficiencies

Pallets, tanks, truck bed liners,

tote bins, tanks, selflubricating tendency makes it
ideal for non-stick/low friction
applications

Difficult to process, high mold

shrinkage

Tool cases, applications with a

living hinge, food containers,
acid tanks

UV sensitive requires a UV
protective cap layer for
extended exposure

Cases of all types, bath tubs,

fenders, instrument panels,
automotive applications,
recreational vehicles, many
others

Difficult to process

Shower surrounds, moldings,

kick panels, display cases

30,000

Low heat distortion point

~160F

Decorative fascia, equipment

covers, mass transportation
applications, outdoor
applications with UV protective
cap, many others
Aircraft interiors, medical
equipment covers,
transportation applications,
electronic enclosures, outdoor
applications with UV protective
cap

Low chemical resistance to

certain substances (oil,
gasoline, harsh chemicals), can
be difficult to process, higher
material and processing cost

Visors, plastic guards,

transportation components
(headlights, taillights,
instrument panels), appliance
drawers, skylights

When compared to true

polycarbonate reduced
clarity, lower heat distortion
~240F

Computer and machine

enclosures, electrical
applications, cellular phones,
automotive applications

Can be difficult to process due

to material sag during heating

Car bumpers and other

automotive applications,
chemical shields, gear covers

Not UV stable unsuitable for

extended exposure

Structural automotive parts,

hand tools, industrial
components

Not as stiff as pure PVC, heat

distortion point lower than ABS

ADE PLASTIC EXTRUSION MATERIALS

Acrylic (PMMA)
ABS
G.P. Polystyrene (GPPS)
gh Impact Polystyrene (HIPS)
d and Flexible (clear and pigmented)
Polypropylene (PP)
olyethylene (LDPE and HDPE)
PETG
SAN
ermoplastic Elastomers (TPEs)
hermoplastic Olefins (TPOs)

RADE PLASTIC EXTRUSION MATERIALS

Geloy (ASA)
Noryl (PPO)
Polycarbonate (PC)
Polysulfone (PSU)