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Plastic materials for injection molding range from commonly used polymers to specialty plastics and polymer blends. There are hundreds of different plastic resins available, and they each have different end-use properties and processing requirements. Plus, there are different grades of the same plastic material, including resin types with fillers such as glass fibers or carbon fibers, and specific brand names.
With so many choices, it&#;s daunting to choose the right material for your project. Whether your project involves medical plastic injection molding, molded plastic components for the automotive industry, or something else, Fictiv experts are ready to help you go from design to production quickly.
And if you&#;re looking for help with your injection molding projects, check out our Guide to Injection Molding Production. This downloadable PDF explains what you need to know to make your next injection molding project a success.
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Otherwise, keep reading to learn about the top 10 plastic injection molding materials.
These are the most common plastic materials for injection molding:
This article discusses their properties, including comparisons to other materials, along with injection molding applications, grades, and brand names for each.
Injection molded acrylicAcrylic is a strong, clear thermoplastic that provides a lightweight, shatter-resistant alternative to glass. This injection-molded material also offers excellent optical clarity so that a high percentage of light passes through. Acrylic resists ultraviolet (UV) light and weather, and is also known as PMMA, or by its full chemical name: poly(methyl methacrylate).
Unlike some plastics, acrylic can withstand exposure to water and hold tight tolerances. PMMA won&#;t absorb odors, but it cannot resist solvents and is easily stained by greases and oils. Although injection-molded acrylic has high tensile strength, it&#;s prone to stress cracking under heavy loads.
Applications for acrylic injection molding include windows, greenhouses, solar panels, bathroom enclosures, and other transparent components for architectural, lighting, and outdoor applications.
General-purpose and specialty grades of PMMA plastics are available, including:
Common brand names for acrylic plastics include Trinseo PLEXIGLAS®, which is available with high heat resistance, and DuPont LUCITE®, which has excellent optical clarity and transparency.
Injection molded ABSABS has a relatively low melting point that makes it easy to mold. This opaque polymer supports the use of colorants as well as various textures and surface finishes. Its butadiene content delivers exceptional toughness, even at low temperatures, and its styrene content imparts a shiny, attractive finish to plastic injection molded parts.
ABS is known for its strength and impact resistance, but it lacks strong resistance to sunlight (UV), water, and weather. Compared to acrylic, injection-molded ABS is not a good choice for outdoor applications. ABS also generates significant smoke when burned and, unlike nylon, provides poor resistance to high friction.
ABS injection molding is used to produce many types of plastic parts, including:
Well-known brands of ABS include Samsung Starex®, Toray Toyolac®, BASF Terluran®, and Ineos Lustran®.
Injection molded nylonNylon is a synthetic polyamide (PA) that combines toughness and high heat resistance with high abrasion resistance, good fatigue resistance, and noise-dampening properties. Nylon isn&#;t inherently flame-resistant, but flame-retardant versions are available. Similarly, although nylon can be degraded by sunlight, a UV stabilizer can be added to improve outdoor performance.
Compared to other plastics, nylon provides poor resistance to strong acids and bases. Nylon is not as strong as polypropylene and can&#;t match polycarbonate for impact resistance. Injection molding nylon is challenging because it&#;s prone to shrinkage and is subject to inadequate mold filling.
Applications for nylon injection molding include:
With its low coefficient of friction, nylon is also well-suited for applications with high-friction and wear.
Nylon comes in four main grades, and each has slightly different mechanical properties:
Nylon can also be filled with glass fibers for greater mechanical strength.
Injection molded polycarbonatePolycarbonate is strong, lightweight, and naturally transparent. This plastic injection molding material has excellent optical properties to support light transmission, but maintains its color and retains its strength when pigmented. Although it isn&#;t scratch-resistant, polycarbonate is significantly stronger than glass and is extremely durable.
Injection-molded polycarbonate is sometimes used instead of acrylic because PC maintains its physical properties over a wider temperature range. PC requires high processing temperatures, however, which can make it more expensive to mold. With its predictable and uniform shrinkage, however, polycarbonate offers precise dimensional control for tighter tolerances.
Applications for polycarbonate injection molding include:
Because it contains the chemical bisphenol A (BPA), polycarbonate is not recommended for food preparation or storage.
Polycarbonate plastic can be filled with glass and is available in grades that contain a relatively small percentage of stainless steel fiber. Popular brands include SABIC Lexan®, which is available in flame-resistant versions, and Covestro Makrolon®, which has glass-like transparency.
There are several major categories of PE plastic.Polyethylene is the most commonly used plastic in the world and is a commercial polymer that can be selected according to its density. High-density polyethylene (HDPE) and low-density polyethylene (LDPE) both provide chemical resistance, but they differ in terms of their hardness, flexibility, melting point, and optical transparency.
PE plastics include polyethylene terephthalate (PET, PETE), a material that is not defined by its density. Like LDPE, PET can be as clear as glass; however, designers can also select grades of PET or PETE with different levels of optical clarity. HDPE, LDPE, and PET all resist moisture and chemicals, but LDPE is softer and more flexible than HDPE, which is an opaque material.
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Applications for polyethylene injection molding may be limited to indoor applications because of their poor UV resistance. Because they are unable to withstand high service temperatures, these plastic materials may not be suitable for some processing applications. Often, injection molded polyethylene is used in products such as housewares, toys, food containers, and automotive parts.
PE plastics come in numbered grades where higher numbers generally indicate higher densities. For example, HDPE 500 has a higher density than HDPE 300. Both grades have a higher density than LDPE, which also uses a numbering system for grades. BASF and DuPont are two of the leading suppliers of PE for engineering (as opposed to general-purpose) applications.
Polyoxymethylene (POM) is an engineering plastic that is also known as acetal. It combines excellent rigidity with thermal stability and has a low coefficient of friction. This plastic material has low water absorption and good chemical resistance. In terms of appearance, POM plastics are naturally opaque and white in color.
In its pure form, acetals have low impact strength and a very high rate of thermal expansion. Yet, POM can be reinforced with fiberglass or minerals for improved strength and stiffness. Compounds that are reinforced with both provide an excellent balance of mechanical properties. Because injected molded POM lacks resistance to sunlight, its outdoor applications are limited.
With its low coefficient of friction, injection-molded POM is used in bearings, gears, conveyor belts, and pulley wheels. Additional applications include fasteners, eyeglass frames, parts for knives and firearms, lock systems, and high-performance engineering components.
There are two main types of acetal plastics: homopolymers, which provide higher hardness and tensile strength, and POM copolymers. Neither type of material can be fire-rated to a standard such as UL 94, and both experience relatively high shrinkage during injection molding. Popular brand names for POM plastics include DuPont Delrin® and Ensinger TECAFORM®.
Injection molded polypropylenePolypropylene is the second most commonly used plastic in the world. It provides good chemical resistance, retains its shape after torsion or bending, has a high melting point, and won&#;t degrade when exposed to moisture or water. Injected molded polypro, as PP is sometimes called, is also recyclable.
Despite its comparative advantages, polypropylene degrades with UV light and is extremely flammable. At temperatures above 100° C (212° F), this injection-molded plastic dissolves into aromatic hydrocarbons, such as benzene and toluene, which are harmful to humans. Polypropylene plastic is also difficult to bond and paint.
Applications for polypropylene injection molding include
Pure polypropylene is a commodity plastic with the lowest density, but high crystalline polypropylene (HcPP) is filled with glass fibers for rigidity. Semitron® from Mitsubishi Chemical Advanced Materials is a leading brand.
Polystyrene plastics are lightweight, relatively inexpensive, and resistant to moisture and bacterial growth. These commodity plastics also provide good chemical resistance to diluted acids and bases and have excellent resistance to gamma radiation, which is used to sterilize medical devices.
There are two main types of polystyrene: general-purpose polystyrene (GPPS) and high-impact polystyrene (HIPS). GPPS is brittle and has less dimensional stability than HIPS, which is compounded with butadiene rubber to enhance its material properties. GPPS also has a glass-like clarity whereas HIPS is opaque.
Applications for polystyrene injection molding include medical, optical, electrical, and electronic applications. With its higher impact strength, HIPS is often used with appliances and equipment, while injection-molded GPPS is used in plastic toys, cases, containers, and trays.
Both materials are flammable and susceptible to UV degradation.
Polystyrene can be filled with glass for added strength or co-polymerized with acrylic for greater clarity and improved chemical and UV stability. Brand names include American Styrenics PolyRenew® and BASF Polystyrol®.
TPE is a blend of plastic and rubber materials. It is processed like plastic but has the properties and performance of rubber. Known also as thermoplastic rubber (TPR), TPE can be stretched to moderate elongations and, upon the removal of this stress, returns to the material&#;s original shape. TPE can also be recycled repeatedly.
Compared to liquid silicone rubber (LSR), TPE is easier and less expensive to mold. Under sustained pressures, however, TPE is susceptible to creep, the tendency of a solid material to permanently deform. TPE also tends to lose its rubbery properties at higher temperatures and is significantly more expensive than other plastic injection molding materials.
Applications for TPE injection molding include:
Automotive applications include weather seals and shock dust boots. Medical applications include breathing tubes, valves, catheters, and ventilation masks.
ISO defines generic classes of commercial TPEs. There are many different manufacturers and brand names, including Teknor Apex Telcar®, Kraiburg HIPEX®, and Dynaflex&#; from Avient (formerly PolyOne). Healthcare-grade TPEs are available.
TPU is a type of TPE that is often called out separately because of its popularity. It has a rubber-like elasticity, and can be used as a replacement for hard rubber because of its higher durometer. Injection-molded TPU also has good load-bearing capabilities and can withstand exposure to ozone.
Compared to TPE, TPU has superior resistance to extreme temperatures and chemicals. TPUs may be too hard for some injection molded plastic parts, and tend to cost more, in part because drying is required before processing.
Applications for TPU injection molding include footwear, gaskets, caster wheels, and sporting goods along with cases or enclosures for electronics and medical devices. In medical applications, TPUs are sometimes used instead of polyvinyl chloride (PVC), a plastic that may cause skin irritation.
Thermoplastic polyurethanes come in commercial, medical, and industrial grades. There are three main classes of TPU materials: polyester, polyether, and polycaprolactone. Trademarked products are available from manufacturers such as Lanxess, Lubrizol, Texin, and Ultralast.
The plastics discussed in this article are the most common injection molding materials &#; including specialty plastics and polymer blends &#; that Fictiv can injection mold for you.
With so many options, it helps to have an expert&#;s advice before choosing a plastic resin for your project. As part of our injection molding service, Fictiv has design and production experts ready to help you make the right choice, and you get design for manufacturing (DFM) feedback along with your quote.
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