Tuesday, 18 November 2025

Evaluating High-Temperature Performance: DMA Comparison of PARA-GF50 vs. PPA(4T)-GF50

Hello and welcome to a new blog post in which we evaluate the high-temperature performance of PARA (PA-MXD6) vs PPA.

When selecting materials for demanding, high-temperature applications, understanding their mechanical performance under heat is critical. Dynamic Mechanical Analysis (DMA) is a powerful tool for assessing how polymers retain their stiffness as temperatures rise. In this post, we compare the high-temperature behavior of two advanced engineering plastics: PA-MXD6-GF50 (50 wt% glass fiber reinforced Polyarylamide) and PPA(4T)-GF50 (50 wt% glass fiber reinforced Polyphthalamide). Both material fall into the category of semi-aromatic polyamides which reflect a resistance towards higher temperatures. In this post we check if this is the case for the both materials. 

DMA Results: Shear Modulus vs. Temperature

Figure 1 presents the dynamic shear modulus (E') of both materials as a function of temperature. The glass transition temperature (Tg) is a key indicator of when a polymer’s mechanical properties begin to decline:

  • PA-MXD6-GF50 (PARA): E' drops sharply at around 85°C, marking its Tg.
  • PPA(4T)-GF50: E' remains stable until approximately 125°C, indicating a higher Tg.

Beyond the glass transition, the differences become even more pronounced. Between 150°C and 200°C, PARA exhibits a slight plateau in modulus before dropping to zero at 250°C. In contrast, PPA(4T)-GF50 maintains a high modulus, retaining around 5 GPa even at 250°C. This demonstrates PPA’s superior ability to withstand elevated temperatures without significant loss of stiffness.

Figure 1: Comparison Dynamic Shear Moldulus E' of PARA-GF50 and PPA(4T).

Thermal Endurance: UL 746B RTI (Strength) Comparison

To further validate these findings, we examined the Relative Thermal Index (RTI, strength at 1.5 mm thickness) according to UL 746B:

  • PA-MXD6-GF50: RTI (strength) = 105°C
  • PPA(4T)-GF50: RTI (strength) = 130°C

The higher RTI value for PPA(4T)-GF50 confirms its suitability for applications requiring long-term mechanical integrity at elevated temperatures.

Ways to increase the thermal performance of PARA / MXD6

Increasing the thermal resistance of PARA/MXD6 can be done by blending PARA with PPE  (Polyphenylenether) and make a MXD6/PPE alloy which not only exhibits high temperature resistance, high strength, but also good and wear resistance.

Conclusion: Material Selection for High-Temperature Applications

DMA provides valuable insight into how materials behave under dynamic loading across a temperature range. For applications operating above 120°C, PPA(4T)-GF50 clearly outperforms PA-MXD6-GF50, maintaining higher modulus and demonstrating better thermal endurance. Alongside DMA, considering the RTI value is essential for making informed material choices in high-temperature environments.

In summary:

  • PPA(4T)-GF50 offers superior high-temperature performance and stability.
  • PA-MXD6-GF50 is suitable for applications up to its Tg and shows property loss at higher temperatures above 200°C.

Selecting the optimal material ensures reliability and safety in demanding thermal conditions. 

Nevertheless, PARA is outperforming PA and PPA in terms of stiffness, combined with excellent surface aesthetics and lowest water uptake allowing for high dimensional stable parts. 

More on PA-MXD6 / PARA here: 

Design Properties for Engineers: The ABCs of Polyarylamide (PARA; MXD6)

Polyarylamide vs Polyamide (PARA vs PA): What are the Major Differences Between PARA and PA (Polymer Material Selection Tip)?

Design Properties for Engineers: The ABCs of Polyarylamide (PARA; MXD6)

PA6.6 vs. PARA - Reducing the Wall Thickness of Injection Moulded Parts (Geometry Optimization Example)

Design Data for PolyArylAmide (PARA; PA MXD6) Selection: Mechanical Properties as Function of Temperature and Humidity

Mastering Injection Molding Tools for High Performance PolyArylAmide (PARA; PA MXD6): 6 Key Steps to Success

Design Properties for Engineers: Superior Gas Barrier Properties of PolyArylAmide (PARA; MXD6)

Check out my Micro Training below too:


And my dedicated Polyarylamide Hub here.

Thanks for reading & #findoutaboutplastics

Greetings,

Herwig Juster

Literature:

[1] https://www.syensqo.com/en/brands/ixef-para

[2] https://plasticsfinder.envalior.com/en/datasheet/ForTii%C2%AE+Ace+MX53/O4A8W

[3] https://www.nexeoplastics.com/types/plastics-database-datasheet?id=2131&product=Ixef%C2%AE&grade=1022

[4] https://www.orinkoplastic.com/PA-6I-6T-And-MXD6-pl60644367.html


Thursday, 13 November 2025

Plastic Part Failure Analysis - Example Breaking of Toy Helicopter Rotor Blades

Hello and welcome to new post in which we discuss one of my plastic part failure studies answering the question: Why did the toy helicopter rotor blades keep breaking?

Ever had a toy fail at the worst possible moment? That’s what happened with a rescue helicopter toy—kids reported the rotor blades snapping during “harder” rescue missions, always at the same spot. As someone who knows the pain of ordering spare parts, I had to dig deeper!

Here’s what I found:

Root Cause: The blades, made from ABS, consistently broke at the injection point—a natural weak spot. When force was applied (think: enthusiastic play!), stress concentrated here, causing failure.

Why Always the Same Spot? The injection point acts like a weak link in a fixed beam. Too much stress, and snap—it breaks right there (Figure 1).

Figure 1: Broken toy helicopter blade - injection molding point as root cause identified. 

How to Fix It?

1. Move the Injection Point: Shift it to the blade’s center using a conical gate, ensuring even filling and less stress (Figure 2).

Figure 2: Moving the injection point to the center allowing for even filling of both blade sides. 

2. Upgrade the Material: Switch to glass fiber reinforced ABS, increasing the needed force to break the rotor blade by 43% (Figure 3)!

Figure 3: Changing from ABS to ABS+GF10 increases the needed force to break the blade. 

3. Combine Both Approaches: For maximum durability.

This is a great reminder: optimal injection molded parts require attention to all five points of the Polymer Product Pentagram—Part Design, Material Selection, Mold Design, Machine Selection, and Molding Process.

Have you faced similar failures? Let’s connect here and share solutions! 

Thanks for reading & #findoutaboutplastics

Greetings,

Herwig Juster

Tuesday, 11 November 2025

Polycarbonate Market Review 2025: Innovation, Growth, and Global Shifts

Hello and welcome to my Polycarbonate Market Review 2025, discussing innovation, growth, and global shifts

Polycarbonate (PC) remains a cornerstone material for modern industry, prized for high impact resistance, optical clarity, and versatility. From automotive and medical to digital electronics and construction, PC and its blends continue to enable the megatrends that define our time.

Why this matters: As global supply chains reset and sustainability moves center stage, the PC market is undergoing meaningful change. In 2024, global PC (including blends) surpassed 5.2 million tons for the first time, and a steady ~4% CAGR is expected— with China and India likely to outpace the global average.


A Material Built for Modern Demands

Pure Polycarbonate offers a rare combination of toughness, transparency, and heat resistance. Its versatility accelerates further through PC blends such as PC+ABS, PC+ASA, PC+PBT, and PC+PET, delivering improved impact performance, heat resistance, stiffness, and chemical durability.

Across digitalization, new mobility, and medical technology, PC and PC blends provide the reliability, design freedom, and performance required for next-generation products.

Market Overview: Recovery Amid Headwinds

Despite structural strengths, producers faced lower demand in recent years and intense competition that pressured prices and margins. European manufacturers contended with higher electricity and gas costs, further tightening profitability.

Even so, momentum is building. The market crossed the 5 million ton threshold in 2024 (5.2 Mt), and forward growth near 4% annually is expected— with faster expansion in China and India.

Global Leaders and Capacity

Two companies account for 40%+ of global PC capacity:

  • Covestro
  • Saudi Basic Industries Corporation (SABIC)

New Chinese entrants—Wanhua Chemical and Zhejiang Petroleum & Chemical (ZPC)—are scaling rapidly, while established players such as Mitsubishi Chemical and Lotte Chemical remain influential.

Capacity and Consumption Snapshot (2024)

  • Production capacity: Asia-Pacific 70% (5.5 Mt; China 3.5 Mt), EMEA 20% (1.4 Mt), Americas 10% (0.8 Mt).
  • End-market usage: Asia-Pacific (incl. China) 70%, EMEA 17%, North & South America 13%. China is the largest single market.

China: The Powerhouse of Growth

China increased PC polymerization plants from 5 (2015) to 17, with exports rising from 250,000 t/y to 500,000 t/y. Notable capacity additions:

  • Hainan Huasheng – 260 kt/y (2022)
  • Sinopec SABIC Tianjin Petrochemical (SSTPC) – 260 kt/y (2022)
  • Hengli Petrochemical – 260 kt/y (2024)
  • Zhangzhou Chimei Chemical – 180 kt/y (2024)
  • Pingmei Shenma – 100 kt/y, with plans to expand to 400 kt/y

Europe: Capacity Contraction and Import Reliance

Trinseo ceased PC production in Stade, Germany; SABIC closed two lines in Cartagena, Spain by end-2023 (now ~130 kt/y). Since 2023, Europe has been the largest net importer of PC, highlighting competitiveness and energy-cost challenges.

The Americas and India: Stability and Ascent

In the U.S., PC production remains stable: SABIC (Indiana, Alabama), Covestro (Texas), and Trinseo (PC compounding). India grew from 125 kt/y (2015) to 300 kt/y. A key milestone: Deepak Chem Tech (DCTL) added 165 kt/y of capacity using Trinseo technology and repurposed equipment from the closed Stade plant—an example of efficient global tech transfer.

Where Polycarbonate Shines: End-Use Segments (2024)

  • Electrical & Electronics (E&E): 35%
  • Automotive: 20%
  • Construction: 15%
  • Consumer goods: 10%
  • Medical, optics, sports, toys, packaging: 20%

Recycling and the Road to Circularity

Three primary routes are advancing PC circularity:

  • Mechanical recycling – efficient for clean, post-industrial streams.
  • Chemical recycling – restoring virgin-like quality; active programs at Covestro, LG Chem, Mitsubishi Chemical, and Wanhua Chemical.
  • Solvent-based recycling – selectively extracts PC from mixed waste; Trinseo’s Terneuzen (NL) pilot, 2023, demonstrates promising results.
Key Data of the Polycarbonate Market Review [1]

Outlook: Resilient and Essential

Despite margin pressure and regional disparities, Polycarbonate remains strategic to innovation in mobility, electronics, healthcare, and sustainable infrastructure. With ongoing capacity investments, stronger Asian supply, and accelerating recycling technologies, the PC market is positioned for steady growth and meaningful transformation in 2025 and beyond.

Thanks for reading & #findoutaboutplastics

Greetings,

Herwig Juster

Friday, 7 November 2025

Wombat: Not Just an Animal—A Lesson for Plastics Operations

Hello and welcome to a new blogpost. When you hear “wombat,” you might picture a sturdy little marsupial from Australia. But in the world of plastics engineering, Wombat stands for something else entirely: 

Waste of Money, Bandwidth, and Time. 

And it’s a concept every polymer professional should keep top of mind.

Wombat in the world of plastics engineering.


Why Wombat Matters in Plastics

In our fast-paced industry, it’s easy to get sidetracked by shiny new technologies, endless data, or meetings that lead nowhere. But every minute and euro spent on non-essential activities is a minute and euro not spent on what really matters: making perfect plastic parts.

Wombat is a reminder to ask ourselves:

  • Are we investing in tools and processes that actually improve quality and efficiency?
  • Is this meeting, report, or project moving us closer to our production goals?
  • Are we focusing on root causes, or just treating symptoms?

Applying Wombat Thinking to the Plastics World

Let’s look at a few practical examples:

  • Material Selection: Don’t over-specify or under-specify. Choose the right polymer for the job, not the most expensive or the one with the flashiest datasheet.
  • Process Optimization: Focus on parameters that truly impact part quality—like melt temperature, cooling time, and pressure—rather than chasing every minor variable.
  • Troubleshooting: When defects arise, use data-driven root cause analysis. Don’t waste time on guesswork or “just try it” fixes.

The Payoff: Perfect Parts, Less Waste

By keeping Wombat in mind, you’ll streamline your operations, reduce scrap, and deliver higher-quality parts—without burning through resources. It’s about working smarter, not harder.

So next time you’re faced with a decision, ask yourself: Is this a Wombat? If it is, steer clear and refocus on what truly drives success in plastics manufacturing.

Let’s leave the wombats in the wild—and keep our operations lean, focused, and efficient!

Thanks for reading & #findoutaboutplastics

Greetings,

Herwig Juster