Introduction to

Polymers, Properties &

Selection
 Knowledge
Of Plastic
Materials
Reliable
Molding Excellent
Machine Part Design

World class
Moldings
Robust
Optimum
Mold Design
Process
Parameters
Methodical
Mold Manufacture Internally consistent &
mutually supportive
 Thorough Excellent
Knowledge Part Design
Of Plastic
Materials Robust
Mold Design
Successful
Injection
Moldings Methodical
Mold Manufacture
Optimum
Process
Parameters
“Internally
consistent &
Reliable mutually
Molding Machine supportive”
What are plastics?

Synthetic - Man made

Organic - Based on carbon

Polymers - Many units

Describes the MOLECULES
of polymers
Properties of Plastics

• Easy to work and shape,

• Have a low production cost,
• Possess low density,
• Can Be colored easily
• Tend to be waterproof,
• Good electrical insulators,
• Acceptable acoustic insulation,
• Good thermal insulation, but most can not withstand very
high temperatures,
• Resistant to corrosion and many chemical factors;
• Some are not biodegradable or easily recyclable, and if they
burn, are highly polluting.
What is polymerisation

polymerization, polymerisation(noun)
a chemical process that combines several
monomers to form a polymer or polymeric
compound
Polymers are Large Macro Molecules made
up of many Micro Molecules
Polymerization

Polymer Chains
Monomer Molecules in Random Motion

Monomer
Classification of Polymers
 Polymer

Semi
Natural Synthetic
Synthetic
Shellac Butyl Cellulose
Rubber Derivatives
Polymerisation example

H H H H H H H H

c c c c c c c c

H H H H H H H H

ETHYLENE
Monomer
 Polymerisation example
Catalyst -heat, pressure and time

H H H H H H H

c c c c c c c c

H H H H H H H H

ETHYLENE POLYETHYLENE
monomer polymer
Polymer examples

Propylene Polypropylene
monomer polymer
Styrene Polystyrene
monomer polymer
Vinyl Chloride Polyvinylchloride
monomer polymer
Phosgene
Polycarbonate
Bis-Phenol Acetone
polymer
monomer
Classifying plastics

Thermosets

Example - Bakelite
Heat
Heat & Pressure
Cross-linking reaction

Melt
Flows due to
pressure Curing/solidification
Polymer Architecture

• Polymer = many mers

mer mer mer
H H H H H H H H H H H H H H H H H H
C C C C C C C C C C C C C C C C C C
H H H H H H H Cl H Cl H Cl H CH3 H CH3 H CH3
Polyethylene (PE) Polyvinyl chloride (PVC) Polypropylene (PP)

• Covalent chain configurations and strength:

Direction of increasing strength

Isomerism –
different structures, but same chemical composition

H H H H H H H H H H

C C C C C
Isotactic
C C C C C
R H R H R H R H R H

H H H H H H H H H H

C C C C C
Syndiotactic
C C C C C
R H H R R H H R R H

H H H H H H H H H H
Atactic C C C C C
Can’t Crystallize
C C C C C
R H H R R H R H R H

Stereoisomerism
Addition Polymerization(Chain Growth)

•Reaction of unsaturated monomers which links to form a

continuously increasing chain

•Initiation step is slow, Propagation & Termination Steps are Rapid

•Monomer Concentration decreases continuously during reaction

•Increased reaction time has no effect on avg. molecular weight

or chain length

•Eg. Polyethylene, Polypropylene,

Polyvinyl Chloride, Polystyrene
Polymerization of Ethylene into Polyethylene

Addition Polymerization
 HomoPolymer and Co polymer

If a polymer consists of only one kind of monomers then it is called a

homopolymer,

When a polymer which consists of more than one kind of monomers is called
a copolymer or a HeteroPolymer.

Types of copolymers
• Block Copolymer,
• Random Copolymer,
• Alternate Copolymer.
• Graft Copolymer

This is based on the arrangement pattern of the various monomers in the

polymer
Types of Copolymers
Condensation Polymerization(Step Growth)

•Reaction of polymers containing specific functional

groups that undergo condensation to a lager
molecule with the release of H2O,HCl,ROH

•Concentration of monomers decrease rapidly,

Concentration of polymer increases gradually.

•Eg. Polyesters, Polyurethanes,

Polyamides, Polycarbonates
 Catalyst
INPUT OUTPUT
1.Monomers
2.Heat Polymerization Polymer +
(water)
3.Pressure

Polymerization Process
# PARTICULARS POLYMERIZATION

ADDITION CONDENSATION

1 Type of Reaction to Simple Addition Condensation

create chemical
linkages between
monomers

Frequency
Molecular Weight
2 Byproduct - Water

3 Example PE,PP Polyamide,

Polyester
Polymerization Reactor
Classification of Polymers with Examples
Classification of Plastics
Plastics

Thermo Thermo set

Elastomers
Plastics Plastics

Semi
Amorphous
Crystalline
•PC , PS •PA , PE, •PF, MF, PU
PP UF
•PVC
Classification of Plastics

Load ,
Temperature,Cost
Super
Plastics

Engineering
Plastics

Commodity
Plastics
 Classification of Plastics
Load ,
Temperature &
Cost
Super
Plastics
PTFE, PEEK,LCP
110 MPa 200°C Rs.1000

Engineering
Plastics
60 MPa PA,POM,PC,ABS Rs.150
85° C

Commodity Plastics
PE,PP,PS,PVC
23 MPa 35° C Rs.50
Table of differences between
Thermo plastic & T.Set
# PARTICULARS THERMOPLASTICS THERMOSETS

1 Linking of Monomers Long linear chains Cross linked (3D)

(with side branches)
without cross linking
2 On application of Soften to from a Gel like soft
Heat viscous melt structure

3 Change on heating Physical Chemical

(Insoluble,
Infusible)
4 Analogy (Example) Ice, Water, Steam Egg & Omelet

5 Recycling Yes No
Thermoplastics:

1.Become soft when heated

2.Easily moulded
3.Remolded without significant degrading
Thermo-sets

1. Rigid plastics
2. Resistant to higher temperatures
than thermoplastics
3. Once set cannot be remolded

31
Elastomers

1.Loosly cross linked compared to

thermosets
2.More Elastic than thermosets
3.Once shaped cannot be reshaped
Thermoplastics : Thermo - sets

Remolded without Once set cannot

significant be remolded
degrading
Effect of ‘n’ value on State of Polymer

n = DOP
H.D.S
> 3000
L.D Solid
n > 1000
Wax 26 < n < 50

Oil 12 < n < 14

Liquid 5<n<8

Gas n = 1
 Injection Molding grade of
Polymers
500 < n > 35,000

DOP Mechanical Melting Viscosity Processabilty

(n) Properties Point
Thermoplastics
Amorphous Semi Crystalline

Branched Chain Linear Chain

molecules molecules
 Amorphous
(a-morphous = without shape)
• Polymer chains in random arrangement
• Molecular structure incapable of forming
regular order (= not crystallized)
• Molecular arrangement randomly twisted,
kinked & coiled

Amorphous

Random order
Crystalline
•Polymer chains form a regular pattern
•Molecular structure forms regular order
(crystals) Regularly stacked in crystal-like fashion
Semi Crystalline
Amorphous

Crystalline
(Orderly)
# PARTICULARS THERMOPLASTICS

AMORPHOUS CRYSTALLINE
1 Order of Structure Random Aligned &
Closely packed
2 Volumetric Shrinkage Less More
3 Transparency Yes No
4 Melt temperature, Melt Less High
viscosity, Shrinkage

5 Toughness & Flexibility More Less

6 Strength in direction of ~Equal in all Higher*
molecules directions
7 Ease of Processing Easy Difficult
8 Example ABS, PC, PMMA, *PP, PE, Nylon
PS, PVC
# PARTICULARS THERMOPLASTICS
AMORPHOUS CRYSTALLINE
9 Softening with Over a broad range Sharp Melting Point
temperature of temperature

10 Bonding with Adhesives Easy Difficult

/ Solvents
11 Stress cracking Prone to Resistant

12 Fatigue Resistance Poor Good

13 Typical Applications Structural only Structural +

14 Bearing / wear No Yes

applications
Deformation Behaviour of Amorphous
Thermoplastics with Temperature
Tensile strength

Temperature
Tg –Glass Transition Temp. T f – Flow Temp. Td–Degradation Temp.
 Tg Tm Td

Rigid Thermo Plastic

Thermo
Brittle
Elastic
Tensile strength

Temperature

Tg –Glass Transition Temp. Tm –Melting Point Temp. Td–Degradation Temp.

 RANGE OF MECHANICAL
PROPERTIES FOR SEVERAL PLASTICS
Position of plastic can be changed by Additives, Fillers, Reinforcements & Alloying
TOUGH

ABS NYLON
POLYACETAL
P.CARBONATE

POLYPROPYLENE PVC
DAP
POLYETHYLENE
EPOXY
ACRYLIC
PHENOLIC

POLYESTER
POLYSTYRENE

BRITTLE
Concept of Polymers-Schematic Analysis
Major Families of Plastics & Their Properties

45
46
Automobile Tyres

Name of Elastomer?

47
Composition
(CH2 –C(CH3)-CH-(CH2)2-C(CH3)2)n

Elastomer Material: Butyl Rubber

• Synthetic
• Resembling natural rubber in properties
• Resistant to abrasion, Tearing
• Low Gas permeability*
• Useful properties up to 1500 C
• Low dielectric constant & Loss making
them attractive for electrical applications

48
Applications -- Butyl Rubber
•Car Tyres
•Seals
•Belts
•Anti-vibration Mounts
•Electrical insulation
•Tubing
•Rubber Lining for Pipes
•Pumps
49
Identify the Elastomer?

50
Composition
(CO –NH-R-NH-CO-O-R-O)n

Please write whether PU is an Elastomer or

Thermoset Plastic or Thermoplastic-
plastic?
51
Elastomer Material: PU
•Soft, Stretchy material & fabric
•Available in all grades of
thermoplastic, elastomers &
thermo set materials
•Easily foamed with a blowing
agent
•Open cell / closed cell, micro-
cellular, Filter grades with
varying Hardnesses
•Strongest of elastomers
52
Application of PU:
•Cushions
•Packaging
•Shoe soles
•Fuel hoses
•Gears
•Bearings
•Car Bumpers
•Adhesives
•Fabric
coating
53
 Thermoplastics

Guess & write the total

Number of Plastics
commercially available

54
15 in Alphabetical Order

55
56
57
Guess what could be this Plastic?

Building Blocks for Children’s Toy

58
Acrylonitrile Butadiene
Styrene (ABS)
•Tough, Resilient &
Easily Molded
•Can be given vivid
colors
•ABS-PVC Alloy > ABS
•Weather resistant
•Can be painted
59
Acrylonitrile Butadiene Styrene (ABS)
Composition
(CH2 –CH-C6H4)n

•Tough, Resilient, Easily

Molded
•Can be given vivid
colors
•ABS-PVC Alloy > ABS
Applications -- ABS:
•ABS-PVC in Power Tool
Casings
•Safety Helmets
•Car Interior components
Business machines
•Wheel Covers
•Boat Hulls
•Weather Seals
•FDA Approved?
Please identify the Polymer
Polymethyl-Methacrylate
(Acrylic, PMMA)
Composition
(CH3 –CH2-C-CO-OCH3)n

Thermoplastic that most closely resembles Glass in

transparency
Resistant to weathering Discovered in 1872; First
commercialized in 1933
First Major Application as cockpit canopies for fighter
aircraft during II WW
Application of Acrylic, PMMA :

•Lenses of all types

•Aircraft windows
•Signs
•Domestic Baths
•Electrical components
•Tool Handles
Application of Acrylic, PMMA :

•Lenses of all types

•Aircraft windows
•Signs
•Domestic Baths
•Electrical
components
Application of Acrylic, PMMA :

Tool Handles
Safety spectacles
Automotive Tail lights
Chairs
Contact lenses
Advertising signs
Source: Article “The Intraocular Lens has
revolutionized Cataract Surgery. A Look at how
it came about” By Dr. J. Agarwal
After WWII, many pilots had pieces of plastic from the
windshields of their bombers embedded in their eyes.
These pieces were inert & did not cause any reaction.
One visionary British Doctor Dr. Harold Ridley wondered if these
pieces could be shaped like a lens & inserted into the eye after
cataract surgery. On Nov.24, 1949 he implanted the first IOL in a
45 year old woman.

67
SPI identification codes
Thermo set Plastics
Advantages of Thermo sets:

1.High thermal stability

2.Resistance to creep & deformation
under load
3.High dimensional stability
4.High rigidity ,
5.High hardness
6.Light weight
7.Excellent electrical insulating properties
8.Low cost
Thermosets

Epoxies

Phenolics
Polyesters
Thermosets
Please identify the
application & guess the
name of the Polymer used
•Write your answer

Phenol Formaldehyde

Distributor Cap
Phenolics

•Commercialized in 1909 triggering a

revolution in Product Design
•Fairly strong
•Can take colors to a certain extent
•Quick & economical Replacement for Ivory
•Stiff, chemically stable
•Good electrical properties

74
Phenolics

•Fire resistant
•Good Insulators
•Resist Heat & chemical
attack exceptionally well
•Easy to mold
•Low in cost
Applications of Phenolics

•Electrical Parts like Switches, Sockets,

Connectors, Relays etc.
•General Industrial Applications
•Water lubricated bearings
•Brake Pistons
•Micro-wave cookware
Applications of Phenolics

•Handles
•Coatings
•Adhesives
•Sandwich structures
•Good choice for Distributor cap shown
General Properties of Plastics
Plastics are much lighter than metals.

Density of Metals ? Density of Plastics ?

Metals Density Plastics Density
Gm/ cc Gm/ cc
Gold 19.3 PTFE 2.1
Silver 10.5 POM (Acetal) 1.4
Copper 8.9 PC / CA 1.2
Iron / Steel 7.85 Acrylic / Nylon 1.15
Alluminium 2.7 ABS / PS 1.05
Magnesium 1.74 HDPE 0.96
LDPE 0.92
PP 0.90
Plastics are much lighter than metals

Which metal competes with Plastics?

Transparent package with excellent impact strength is moulded out of Acrylic
 TRANSPARENCY %

GLASS 90

PMMA 92

PC 89

87 88 89 90 91 92 93
 Optical Properties

Transparency Translucency Opacity

83
84
Varieties of parts with excellent mechanical, Chemical and
Electrical characteristics can be moulded from plain & glass
reinforced (ETFE) Fluro - polymer resins

85
 Dynamically
stressed
(Moderate)
parts

Fan Blade& Blower wheel moulded of

Mineral reinforced Nylon

86
Dunnage Tray --- HDPE
Weight --- 13.5 Kg –
can carry pay load – 2.75 Tons

High
Strength
to
Weight
Ratio

87
Moulded Bakery Tray
Material : Glass reinforced PP
Less weight. problem - Sticking
of baked items to Tray avoided
Temperature
Resistance

88
Packaging applications :-
Thermoformed Egg Cartons from
Foamed extruded Polystyrene
sheet

89
Sandwich Structure

Solid Skin Solid Skin

Foamed Enlarged Photo of ‘Sandwich

Core moulded’ product

90
Concrete Shutter Trough
Favorable Stiffness to weight Ratio

Solid Foamed
PP Skin PP Core

Concrete Shutter Trough with solid

Polypropylene skin and Foamed PP core

91
Multi-color / Multi-Polymer capability

Sandwich Moulding machine -- Clamping capacity 1500 Tons.

92
 Easy Formability of Intricate Shapes

HIPS Decorative Panel

Acrylic Sink
*

HIPS Drawer

Thermoformed Products : --- a) Acrylic Sink b) HIPS drawer

c) HIPS Decorative Panel d) Wood-grained Plastic skin
Laminated to chip Wood base

*Wood-grained Plastic skin laminated to chip wood base

93
 Finishability

Sailboat hull formed out of

ABS sheet & filled with
expanded Polystyrene for
buoyancy

94
THERMOFORMED PARTS

95
THERMOFORMED PARTS

96
Easy Process-abilty

Removing ABS Boat-hull with PS foam

floatation from Press
97
Easy Assemblabilty

Tool & Tote Box vacuum formed of Polyethylene

98
Platability

Blow moulded Acetal copolymer aerosol container

99
Rotationally moulded
Poly Ethylene Hobby Horse

100
Light Weight & Durability

Stylish Ladies Boots Slush moulded from Plastisol --- Semi rigid heels &
soles Flexible uppers with expandable sides & Foam liner
101
Bucket Seat with
rotation molded
HDPE Structural Shell

102
103
104
Aesthetic Appeal

105
Barbie Dolls

106
 Rotomolded
Play Balls
out of
Plastisol

Rotomoulded Vinyl Ball -

Rotation moulded from Plastisol

107
Eg. Casserole

108
Seamless Nylon Fuel
Tank for Boats
Characterized by

1.Light weight
2.Corrosion
Resistance
3.Low Permeation
Treatment
109
Cast Polyester -- Chair back

110
GFR Epoxy Mold

8.3 meter Long weighing 2.75 Kg. (can withstand 2050C)

111
 Electrical Conductivity of Different Materials m/Ohm mm2

COPPER 58.5

ALUMINIUM 38.5

STEEL 5.6

PLASTIC

0 10-15
10 20 30 40 50 60 70

PLASTIC STEEL ALUMINIUM COPPER

Series1 5.6 38.5 58.5

112
Non conductive Reinforced
Plastic Ladders &
Platforms protect linemen
constructing HT Transmission
lines
Very small to Very Large Parts

Mould for 75
Feet Reinforced
Plastic Yacht

114
Tub Shower

Telephone
Booth?

115
 IMD?

In-mould Decoration of
Compression moulded Phenolic
Handles and inserts
116
 IMD

In mould Decoration of Injection

moulded Polystyrene cannisters

117
Automotive Applications:
•A.C Fan
•Oil Suction Tube
•Thrust Washer
•Oil Seal
•Switch Housing
• Bush Bearing………..

What mind can imagine….!

118
Note : AIR & PLASTICS are Heat Insulators

THERMAL CONDUCTIVITY OF MATERIALS

W/mK

COPPER

ALUMINIUM

STEEL 0.15 - 0.5

PLASTIC 0.05

AIR

0 100 200 300 400 500

Insulators ……………………Conductors

119
•Reason for low thermal conductivity of
Plastics?
•Advantage of poor ?
•Disadvantage of poor ?

120
•Reason for low thermal conductivity of Plastics?
•Absence of free mobile electrons
•Advantage of poor ?
•Heat insulating Handles for utensils
•Disadvantage of poor ?
•Heat required for processing can only be
slowly introduced & it is difficult to dissipate
the heat upon completion of processing

121
Thank You