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2. Material selection
Conventional thermoplastics
The materials most frequently used in injection-moulding are thermoplastics. These may be
subdivided into amorphous and semi-crystalline plastics (Fig.1).
These two groups differ in molecular structure and in all the properties that are influenced by
crystallization (Fig. 2).
As a broad generalization, semi-crystalline thermoplastics are used mainly for components that are
exposed to high mechanical stresses, while amorphous thermoplastics are more often employed in
housings because of their lower tendency to warp.
Thermoplastics
amorphous semi-crystalline
PC Polycarbonate PE Polyethylene
PP Polypropylene
Thermoplastics
Fig. 1
4
TOP TEN DESIGN TIPS
By Jürgen Hasenauer, Dieter Küper, Jost E. Laumeyer and Ian Welsh
amorphous semi-crystalline
Mechanical properties O +
Tendency to creep + O
Chemical resistance – +
Notch sensitivity – O
Service temperature O +
Fig. 2
60
150
%
100 40
50 20
0 0
unreinforced 20% 30% 40% 50% unreinforced 20% 30% 40% 50%
Glass fibre reinforcement Glass fibre reinforcement
Comparison of thermal
Comparison of elastic modulus values stability values 1,8 MPa
15000
300
N/mm2
10000
200
°C
5000 100
0 0
unreinforced 20% 30% 40% 50% unreinforced 20% 30% 40% 50%
Glass fibre reinforcement Glass fibre reinforcement
Fig. 3
5
TOP TEN DESIGN TIPS
By Jürgen Hasenauer, Dieter Küper, Jost E. Laumeyer and Ian Welsh
To demonstrate these effects, test bars were milled from injection moulded sheets in the longitudinal
and transverse directions and their mechanical property values were compared in a tensile testing
machine (Fig. 4).
In the case of 30% glass-fibre-reinforced PET, there was a strength loss transverse to the direction
of flow of 32 % for tensile strength, 43 % for flexural modulus and 53 % for impact strength.
These losses must be taken into account in strength calculation by incorporating safety factors.
A wide variety of reinforcing materials, fillers and modifiers are added to many different thermoplastics
to alter their property profiles. In material selection, the changes in properties produced by these
additives must be checked very carefully in brochures or databases (e.g. Campus) or, better still,
technical advice should be sought from specialists employed by the raw material manufacturers
(Fig. 5).
Test bar
Gate Flow direction
Fig. 4
Glass fibres 60
Minerals 40
Aramid fibres 20
Elastomers 15
UV stabilizers 1
Flame retardants 20
organic
inorganic 40
Antistatic agents 5
Effects of additives
Fig. 5
6
TOP TEN DESIGN TIPS
By Jürgen Hasenauer, Dieter Küper, Jost E. Laumeyer and Ian Welsh
Effect of moisture
Some thermoplastics, especially PA6 and PA66, absorb moisture. This may have considerable effect
on their mechanical properties and dimensional stability. Particular attention should be paid to this
property in material selection (Fig. 6- 7).
moist dry
Strength
Strain
Elastic modulus
Impact strength
Dimensions
Weight
Electrical properties
Effect of moisture
Fig. 6
0 10 20 30 40 50 60 70 80 90 0 5 10 15 20 25
moist
Fig. 7
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TOP TEN DESIGN TIPS
By Jürgen Hasenauer, Dieter Küper, Jost E. Laumeyer and Ian Welsh
Profitability analysis
Prototypes wall thickness and production time,
multifunctions,
mould, model
injection moulding conditions,
number of mould cavities,
predrying pellets,
Test methods recycling sprue waste …
Fig. 8
8
EUROPE/MIDDLE EAST/AFRICA Magyarország Ukraine ASIA-PACIFIC Crastin pbt ®
Tynex ®
Antoon Spinoystraat 6 Tel. +36 23 509 400 3, Glazunova Street 168 Walker Street Delrin
acetal resin
parts and shapes
B-2800 Mechelen Telefax: +36 23 509 432 Kyiv 252042 North Sydney NSW 2060
Tel. +32 15 44 14 11 Tel. +380 44 294 96 33 / 269 13 02 Tel: +612 9923-6111 ® Zytel ®
Telefax +32 15 44 14 09 Maroc Telefax +380 44 269 11 81 Fax: +612 9923 6011 Hytrel
thermoplastic
nylon resin
Deborel Maroc S.A. polyester elastomer
Bulgaria 40, boulevard d’Anfa – 10° United Kingdom Hong Kong/China Zytel ®
htn
high performance
Serviced by MA-Casablanca Du Pont (UK) Limited DuPont China Ltd. Minlon ®
polyamide
Biesterfeld Interowa GmbH & Co. KG. Tel. +212 227 48 75 Wedgwood Way 26/F, Tower 6, The Gateway, mineral reinforced
nylon resin
See under Österreich. Telefax +212 226 54 34 Stevenage 9 Canton Road Zenite ®
lcp
Hertfordshire SG1 4QN Tsimshatsui, Kowloon, Hong Kong ® liquid crystal polymer
Ceská Republika a Norway / Norge Tel. +44 1438 734000 Tel: +852 2734 5345 Rynite
thermoplastic
pet
Slovenská Republika Distrupol Nordic Telefax ++44 1438 734109 Fax: +852 2724 4458 polyester resin
DuPont etpv ™
L-13906