The term plastic refers to synthetic or semi-synthetic polymer materials that can be shaped into various forms. High-strength plastics include engineered thermoplastics and thermoset plastic composites. These plastics are valuable raw materials for rigid applications in industries such as aerospace, engineering, and electrical.
Thermoset plastics are suitable alternatives to materials such as metal due to properties like malleability, versatility, and durability. They also offer significant cost savings compared to other materials. Below are the benefits of plastics over metals and other elements that make them suitable for various applications.
High Strength-to-Weight Ratio
A material’s strength-to-weight ratio is a crucial metric that helps determine its suitability for various applications. High-strength plastics can offer favorable strength-to-weight ratios, combining low weight with the tensile and flexural strength needed to withstand demanding loads. This combination makes them useful for weight-critical aerospace and automotive applications, where reducing weight can improve fuel efficiency and lower energy consumption.
Different plastics have varying strength-to-weight ratios, depending on their type and formulation, making them suitable for differing applications. For instance, composite plastics’ high specific strength gives them metal-like durability while maintaining advantages like corrosion resistance and design flexibility. The tenacity comes from the lightweight reinforcements used to create this type of plastic, such as Fiberglas and carbon fiber.
Durability
Plastics consist of a long chain of polymers that contribute to their durability and resistance to everyday wear. Many resist decomposition, but their long-term performance depends on the material and its exposure to sunlight, moisture, and temperature changes. Some grades can perform for decades when selected for the application and environmental conditions.
Unlike metals, plastics do not rust, although their resistance to chemical attack varies by material and exposure conditions. Appropriately selected plastics can resist damage from acids, bases, lubricants, paint strippers, and other substances.
Their durability and chemical resistance can make them suitable alternatives to metals in demanding industrial environments. Examples include marine, chemical processing, and offshore applications.
Composite plastics can absorb and distribute energy from sudden impacts, helping limit damage. Their impact resistance depends on the resin, reinforcement, and application. Some composites also offer strong fatigue resistance under repeated loading, which can cause metals to crack or fail over time
Design Flexibility
Plastics offer design flexibility for industries that need customized forms and structures. They can accommodate a wide range of shapes, sizes, textures, and features to meet specific requirements. This versatility comes from selecting suitable material formulations, densities, and manufacturing processes.
Modern techniques like plastic injection molding and computerized numerical control machining allow manufacturers to create highly complex designs and geometries. In injection molding, thermoplastics soften when heated and solidify when cooled, allowing them to be remelted and reshaped. However, repeated processing can degrade the material and affect its strength and structural integrity.
On the other hand, CNC machining automates thermoplastic prototype development, cutting, shaping, and spinning. Various types of CNC machines produce plastics in different shapes and forms, including the following.
- CNC mills: A cutting tool that shapes plastic from a block of raw material using a rotating spindle.
- CNC lathes: The material attaches to a spinning spindle that cuts around it as directed by computer-fed prompts.
- CNC routers: Routing involves using a rotary tool to slowly cut away from a material.
Easier to Produce
Manufacturing plastic is easier and more efficient today than ever, thanks to improved processes and lower raw material costs.
For instance, CNC machining automates plastic manufacturing to reduce labor costs and margins of human error, producing high-quality thermoplastic products with the correct strength and density. Additionally, CNC machines enhance production speeds and eliminate manual repetition through pre-programmed software with specific prompts.
Other methods that have made it easier to produce plastic include the following.
- Injection molding: This approach commonly used to manufacture thermoplastics and small, high-volume components involves pushing a thermoset material into a heated mold and allowing it to cure.
- Compression molding: Applying heat and pressure turns materials into complex shapes with high dimensional stability, resulting in thermoset composite plastics.
- Blow molding: Manufacturing lightweight and durable hollow plastic products like bottles involves melting plastic and using compressed air to expand it in the mold cavity.
Raw materials required for plastic production are readily available and not subject to the price fluctuations of petroleum-based products and organic ores. That’s because petrochemicals, natural gas, and crude oil are accessible worldwide, and so are recycled post-consumer and post-industrial plastics. The high demand for plastics also contributes to a lower cost per unit and significantly drives down production expenses.
Good Insulators
Plastics’ poor conductivity makes them excellent thermal and electrical insulators, allowing for better design flexibility in applications requiring temperature control. The construction industry extensively uses plastics like spray foam and foam boards because these materials reduce heat transfer between the building’s interior and exterior to maintain stable indoor temperatures.
Thermoset plastics insulate electrical wires, cables, and circuit boards to reduce the risk of electrical short circuits and shocks. Curing and hardening them ensures they don’t melt or deform due to high heat or electricity.
The automotive and aerospace industries use plastic to thermally insulate seats and other furniture upholstery to prevent extreme temperature changes that could cause discomfort for the occupants. However, metals and ceramics are more desirable in applications requiring high thermal conductivity. These include industrial processes where heat dissipation is necessary or when electrical devices need cooling.
Reach out to Atlas Fibre for High-Quality Plastics
Atlas Fibre is North America’s largest manufacturer and distributor of thermoset composite plastics. We use CNC machining to produce thermoset materials for various applications requiring high strength, durability, and impeccable insulation. Our dedicated team can answer all your questions and help you find the best thermoset composite plastic for your application and budget.
Contact us today to learn more about our plastic offerings or request a free quote.