THE THERMOSET DIFFERENCE:

thermoset vs. thermoplastic

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 Thermoplastics vs. Thermosets
A thermoplastic is a polymeric material or plastic that becomes soft and formable when heated
and rigid when cooled. This process may be repeated a number of times without chemically
altering the material.

A thermoset is a polymeric material that undergoes irreversible chemical changes when it is

cured through heat, catalysts, or ultraviolet light: cross-linking prevents movement of molecu-
lar chains after curing. Once cured, the structure cannot be altered.

THERMOPLASTICS THERMOSETS
Pros Pros
High Impact Strength Easy to process and laminate
Attractive Surface Finish May not need pressure or heat to form

Recyclable / Scrap is Reusable Typically inexpensive

No Emissions Typically stronger than thermoplastics
Can bond to other thermoplastics Better suited to higher temperatures
Can be molded or shaped by reheating

Cons Cons
Typically will soften with heat Often release emissions known as volatile
organic compounds (VOCs)

More difficult to prototype Non-recyclable and cannot be reclaimed easily

Short workable pot life, with some exceptions

Thermoplastic Materials
Name Properties Applications and Uses
Acetal Extremely rigid, high melting point, high Gears, bearings, bushings, cams, housings, convey-
strength, good frictional properties, resistance to ors, plumbing fixtures, gas tank caps, automotive
fatigue door handles, seat belt components, and zippers
Acrylics Exceptional resistance to long-term exposure Swimming pools, skylights, sinks, washbasins, room
to sunlight and weathering, outstanding clarity, dividers, and the tail lights on automobiles
good light transmission
Acrylonitrile-Butadi- Outstanding impact strength and high mechani- Appliances, automotive parts, pipe, business ma-
ene-Styrene (ABS) cal strength, great as a substrate for metalizing chines, telephone components, shower heads, door
handles, faucet handles, and automotive front grilles
Nylon Known for their stability and adaptability Automotive parts, electrical and electronic applica-
tions, and packaging

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 Thermoplastic Materials
Name Properties Applications and Uses
Polyamide-Imide Exceptional mechanical, thermal and chemical Aerospace, heavy equipment, and automotive
resistant properties
Polyarylates Known for its strength, toughness, chemical Automotive, appliances, electrical and electronic
resistance, and high melting points applications, ovenware, and outdoor lighting
Polybutylene Known for high flexibility, resistance to creep, Pipe and packaging film
resistance to cracking, and chemical resistance
Polycarbonate Excellent electrical insulating characteristics, Appliances, and electrical and electronic applica-
strong, and rigid tions
Polyethylene Available in a range of flexibilities and properties, Packaging films, house wares, toys, containers,
rigid, and moisture resistant pipes, drums, gasoline tanks, and coatings
Polyketones Resistant to solvents and has great mechanical Appliances, industrial applications, electrical and
properties electronic applications, automotive applications,
bearings, gears, hoses, and tubing
Polyphenylene Low moisture absorption levels, good electrical Electrical and electronic applications, appliances,
Oxide, Modified properties over a wide range of humidity and automotive parts, business machine parts
temperature ranges, resistant to most chemicals
Polyphenylene Excellent heat resistance, as well as outstand- Electrical and electronic applications, and automo-
Sulfide ing chemical resistance, high stiffness and good tive parts
retention of mechanical properties at elevated
temperatures
Polypropylene Light-weight material, about 95% air and has Packaging and foodservice products, automotive
very good insulation properties parts, toys, house wares, appliance parts, wall tiles,
radio and TV housings, furniture, floats, and luggage
Styrene Acrylonitrile Good chemical resistance, high heat resistance, Automobile instrument panels and interior trim and
great clarity, good dimensional stability, and house wares
high rigidity
Sulfone Polymers heat-resistant, can be molded to tight tolerances, Electrical and electronic applications and automo-
exhibit low creep, excellent oxidation resistance, tive parts
and compressive strength
Thermoplastic Poly- Highly crystalline, hard, strong and extremely X-ray film, magnetic tape (audio, video and comput-
ester (Saturated) tough er); packaging; metalized film, strapping and labels

Thermoset Materials
Name Properties Applications and Uses
Alkyds Excellent heat resistance, dimensionally stable Electrical applications like circuit breaker insulation,
under components,excellent dielectric strength switchgear, cases, housings, capacitor and resistor
encapsulation, automotive parts, and coatings
BMC (Bulk Molding Highly rigid, impact resistant, exceptional physi- Appliance parts, electric and electrical components,
Compound) cal and aesthetic properties, high strength-to- HVAC components, industrial light housings, auto-
weight ratio motive, recessed lighting baffles
Diallyl Phthalate Virtually no post-mold shrinkage, high impact Cross-linking agent, thermosetting molding pow-
(DAP) resistance, resistant to sudden and extreme ders, casting resins, and laminates, military, electron-
jolts and severe stresses, recommended for very ic components
high temperatures, chemical resistant, fungus
resistant
Epoxy Virtually no post-mold shrinkage, high impact Adhesives, protective coatings in appliances, indus-
resistance, resistant to sudden and extreme trial equipment, aircraft components, pipes, tanks,
jolts and severe stresses, recommended for very pressure vessels, tooling jigs, and tooling fixtures
high temperatures, chemical resistant, fungus
resistant

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 Thermoset Materials
Name Properties Applications and Uses
Melamine-Formal- Extreme hardness, excellent colorability proper- Rugged dinnerware, household goods, various elec-
dehyde ties, and arc-resistant non-tracking characteris- trical applications, bonding, adhesives, and coatings
tics.
Phenolic Excellent dielectric strength, great mechanical Adhesives, casting resins, laminating resins, electri-
strength and dimensional stability, resistant to cal and electronic Applications, automotive, appli-
high heat, wear resistant, low moisture absorp- ance handles, frac balls, and knobs
tion, can be machined easily
Polyimides Known for thermal stability, good chemical resis- Electronics, medical tubing, adhesives, gears, covers,
tance, excellent mechanical properties, exhibit bushings, piston rings, and valve seats
very low creep and high tensile strength, inher-
ently resistant to flame combustion, most carry a
UL rating of VTM-0
SMC (Sheet Molding Very high volume production ability, excellent Electrical applications, corrosion resistant needs,
Compound) part reproducibility, and it is cost effective. structural components at low cost, automotive, and
transit
Thermoset Polyester Low cost, high strength-to-weight ratio, stability, Appliance parts, electric and electrical components,
great retention of physical properties at high HVAC components, industrial light housings, auto-
temperatures motive, recessed lighting baffles
Urea-Formaldehyde Very hard, scratch-resistant material with good Electrical and electronic products, decorative prod-
chemical resistance, electrical qualities, and heat ucts, laminates, and chemically resistant coatings
resistance

Thermoset as a Metal Alternative

Thermoset plastics have been successful in replacing traditional metal materials where they can
provide value through improved performance at a lower cost.

Thermoset Performance Benefits: WATER TANK CONVERSION

- Less Weight Significant cost savings were
- Design flexibility achieved by converting this
- Dent resistance stainless steel part to plastic.
- Corrosion resistance The part is used inside the
steamer boxes of fast food
- Heat resistance steamers for food preparation.

Thermoset plastics are well suited to demanding requirements because they have the capa-
bility to withstand heat and pressure for long periods of time without failure, they are impact
resistant, and they have exceptional electrical insulating properties. Their dimensional stability,
creep resistance, chemical resistance, stiffness, and high temperature capabilities make them
the preferred material where reliable performance in adverse conditions is imperative and can
be used as a cost-savings alternative for metals.

Phenolic and Polyesters are the two most commonly used materials for metal replacement. The
ability to mold these materials into complex shapes makes them cost effective and also elimi-
nates the need to machine features of a design which allows for closer tolerances. Dimensional
stability of these materials guarantees that close tolerances can be controlled and repeated
continually within ten-thousandths of an inch.

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