Tuesday, 19 November 2024

High Performance Thermoplastic Selection - Imide-Based Polymers (PEI, PAI, PESI, TPI, PI) and Polybenzimidazoles (PBI, PBI+PEEK, PBI+PEKK) [Part 2B]

Hello and welcome to the Part 2B of our High Performance Thermoplastics selection blog series. Today we discuss imide-based polymers and Polybenzimidazoles, their chemistry and production processes, their main properties, processing methods, and applications.

We will discuss six major high performance thermoplastics families (“the magnificent six”) which are outlined in the following enumeration

1. Introduction to High Performance Polymers

2. Short profile of the "magnificent six" families:

-Part 2A: Polysulfides (Polyphenylene sulfide - PPS), Polysulfones (PSU, PESU, PPSU), and Polyarylates (PAR)

-Part 2B: Imide-Based Polymers (PEI, PAI, PESI, TPI, PI) and Polybenzimidazoles (PBI, PBI+PEEK, PBI+PEKK)

-Part 2C: Polyether (PPE, PAEK, PEEK, PEKK)

-Part 2D: Liquid Crystal Polymers (LCP) and High-performance Polyesters (Polycyclohexylene terephthalate - PCT)

-Part 2E: Semi- and Fully Aromatic Polyamides (PARA, PPA, Aramid)

-Part 2F: Polyhalogenolefins (PTFE, PCTFE, FEP, PVDF, ECTFE)

Imide-Based Polymers (PEI, PAI, PESI, TPI, PI) 

Polyetherimide (PEI)

In the 1980s, Joseph G. Wirth developed PEI at General Electric’s Plastics Division and it found its way into the market as Ultem. When Saudi Basic Industries Corporation (SABIC) bought the GE Plastics business in 2007, it took over the PEI patents and continued its marketing and development. 

Chemistry and Production Process

Polyetherimide (PEI) is an amorphous high-performance polymer known for its excellent thermal stability, mechanical strength, and electrical properties. Its chemical structure consists of aromatic rings linked by ether and imide groups. This unique structure contributes to its exceptional properties.
The production of PEI typically involves a multi-step process. One common method is the reaction between bisphenol A and trimellitic anhydride. This reaction forms a precursor, which is then subjected to thermal imidization to yield the final PEI polymer.

Main Properties
  • Excellent Thermal Stability: PEI exhibits outstanding resistance to high temperatures, making it suitable for applications in harsh environments. The glass transition temperature (Tg) is at 217°C and the Relative Thermal Index (RTI) of PEI is 180°C.
  • High Mechanical Strength: It possesses excellent tensile strength, flexural strength, and impact resistance.
  • Good Electrical Properties: PEI offers good dielectric strength, arc resistance, and low moisture absorption, making it ideal for electrical and electronic applications.
  • Chemical Resistance: It is resistant to a wide range of chemicals, including acids, bases, and solvents. PEI is able to retain its strength and resist stress corrosion cracking when exposed to aliphatic hydrocarbons, alcohols, automotive and aircraft fluids, acids, weak aqueous solutions , and acids.
  • Flame Retardancy: PEI is inherently flame-retardant, reducing the risk of fire hazards.
  • Transparent: PEI can be colored, both transparent and opaque. 
  • Biocompatibility: For example Ultem 1010 is biocompatible and it holds NSF 51 certification for food contact. Additionally, it is capable of withstanding steam sterilization.
  • Alternative to Sulfones: PEI is an alternative to replace Polysulfones in certain applications. PEI has a higher UV resistance compared to PSU, PESU, and PPSU. Also, PEI has good mechanical properties, together with low moisture uptake and higher dimensional stability. Figure 1 compares the properties of PEI and Polysulfones (PSU, PESU, and PPSU).
Figure 1: Property comparison of PEI vs Polysulfones (PSU, PESU, PPSU).
  • Low smoke generation: in case of burning, PEI generates low amounts of smoke, making it an ideal interior material for railway, aeroplanes, and aerospace applications. Additionally, it shows low toxicity making it a material which performs excellent in Flame, Smoke, Toxicity (FST) tests.
  • Flexible: PEI is flexible and can be used in simple spring applications as well as for frame in eyewear.
Processing Methods

PEI can be processed using various methods, including:
  • Injection Moulding: This method is commonly used to produce complex parts with high precision.
  • Extrusion: PEI can be extruded into films, sheets, and profiles.
  • Thermoforming: This process allows for the shaping of PEI sheets into various forms.
  • Additive manufacturing: apart from the costly materials such as PEEK and PEKK for 3D printing, the amorphous PEI is a more economic alternative. It is used as a filament for FDM 3D printers, and it is compatible with high-performance FDM/FFF printers (incl. Stratasys printers).
Applications

PEI's exceptional properties make it suitable for a wide range of applications:
  • Electronics: It is used in printed circuit boards, connectors, and other electronic components due to its excellent electrical properties and thermal stability.
  • Aerospace: PEI is employed in aircraft components, such as engine parts and structural elements, owing to its high temperature resistance and mechanical strength.
  • Automotive: It is used in automotive components, including under-the-hood parts, due to its resistance to heat, chemicals, and mechanical stress.
  • Medical Devices: PEI's biocompatibility and sterilisation resistance make it suitable for medical devices like surgical instruments and medical device housings.
  • Food Processing Equipment: Its chemical resistance and high temperature tolerance make it ideal for food processing equipment.
Main manufacturer and trade names

SABIC: Ultem™ PEI, Siltem™ polyetherimide(PEI)-siloxane copolymer, Extem™ amorphous PI

Economic Aspects

PEI is a high-performance polymer, and its cost is generally higher than that of more common plastics. However, its exceptional properties often justify the higher cost, especially in demanding applications where performance is critical.
In conclusion, Polyetherimide (PEI) is a versatile high-performance polymer with excellent thermal, mechanical, and electrical properties. Its wide range of applications, coupled with its superior performance, makes it a valuable material in various industries.

Polyamide-Imide (PAI): An amorphous high-performance polymer which can be still melt processed

Polyamide-Imide (PAI) is an extremely strong, rigid and wear-resistant high performance polymer with use temperature form -200°C till up to 260°C.  Additionally, PAI can keep its mechanical properties over the whole use temperature range and is not melting when reaching the glass transition temperatures. Reason is a post curing process after processing turning the material into a thermoset-like structure. In 1973, chemical company Amoco introduced PAI as Torlon® to the market. Nowadays, the newly formed chemical company Syensqo, which routes back to Ernest Solvay and the Solvay company, produces and market this high performance polymer. 

Chemistry and Production Process

Polyamide-imide (PAI) is a high-performance polymer that combines the properties of polyamides (nylons) and polyimides. It is synthesized through a multi-step process involving the reaction of diamines with dianhydrides. The resulting polymer chains have alternating amide and imide groups, providing a unique combination of properties.

Main Properties

PAI exhibits a remarkable set of properties:
  • High Temperature Resistance: With a glass-transition temperature (Tg) of 275°C, PAI can withstand continuous use at temperatures up to 260°C and short-term exposure to even higher temperatures.
  • Excellent Mechanical Properties: It offers high tensile strength, flexural modulus, and impact resistance.
  • Chemical Resistance: PAI is resistant to a wide range of chemicals, including acids, bases, and solvents.
  • Good Electrical Properties: It has low dielectric constant and dissipation factor, making it suitable for electronic applications.
  • High compressive strength: PAI has a compressive strength which is double that of PEEK when unfiled. Compared to PEI it is about 40% higher.  
  • Extreme low wear and friction: PAI has a dynamic friction coefficient around 0.4; by adding additives such as graphite, it can be lowered to 0.3.
Figure 2: Wear during dry running of PAI vs PI and PTFE.

  • Flame Retardancy: PAI is inherently flame-retardant, reducing the risk of fire.
  • Dimensional Stability: It exhibits excellent dimensional stability, maintaining its shape even at high temperatures. It has a low thermal expansion, even with reinforcements (low CLTE values). 
  • Moisture uptake: PAI absorbs water up to 3.5%, however with a controlled curing process, water can be removed and extreme dimension stable parts in injection moulding with only 1% shrinkage.
Processing Methods

Due to its high melting temperature, PAI is typically processed using specialized techniques:
  • Injection Moulding: High-temperature injection moulding machines are required to process PAI.
  • Extrusion: PAI can be extruded into films, sheets, and profiles.
  • Compression Moulding: This technique is suitable for complex shapes and parts with a diameter larger than 25 mm. 
  • Machining: PAI can be machined for creating prototype parts or precision finished parts.
Applications

PAI's exceptional properties make it suitable for a wide range of applications:
  • Aerospace: Components like engine parts, hydraulic systems, and structural elements.
  • Automotive: High-temperature components such as engine covers, turbocharger housings, and under-hood components.
  • Electronics: Printed circuit boards, connectors, and electronic packaging.
  • Industrial Machinery: Bearings, gears, and other high-performance components.
  • Medical Devices: Sterilizable components and peristaltic pump rollers and bushings for prosthetics (long life due to low wear).
Trade Names and Economic Aspects
  • Syensqo (former Solvay): Torlon PAI
The cost of PAI is higher than that of many other engineering plastics due to its complex manufacturing process and high-performance properties. However, its long-term durability and reliability often offset the initial cost.

Polyamide-imide (PAI) is a versatile high-performance polymer that offers a unique combination of properties. Its excellent thermal, mechanical, and chemical resistance make it a valuable material for demanding applications across various industries.

Polyimides (PI): A Versatile Polymer

Introduction

Polyimides (PIs) are a class of high-performance polymers renowned for their exceptional thermal and chemical resistance, mechanical strength, and electrical insulation properties. PIs show a wide range of use temperatures, from cryogenic up to 400°C and the mechanical properties remain the same in this range. PIs combine low thermal expansion, high wear resistance, and low creeping with high purity and low off-gassing. Their unique combination of properties makes them indispensable in a wide range of applications, from aerospace and electronics to automotive and medical industries.

Chemistry and Production Process
  • Chemistry: PIs are synthesized through a two-step process involving the reaction of a dianhydride with a diamine. This reaction, known as polycondensation, results in the formation of a polyamic acid, an intermediate product. The polyamic acid is then subjected to thermal or chemical imidization to form the final polyimide.
  • Production Process:
1. Monomer Synthesis: High-purity dianhydrides and diamines are synthesized through various chemical processes.
2. Polymerization: The monomers are reacted in a suitable solvent to form a polyamic acid solution.
3. Imidization: The polyamic acid solution is converted into polyimide through thermal curing or chemical imidization. Thermal curing involves heating the solution to drive off water and form the imide rings. Chemical imidization uses a dehydrating agent to accelerate the process.
4. Processing: The polyimide can be processed into various forms, such as films, fibers, coatings, and composites, depending on the desired application.

Main Properties
  • Excellent Thermal Stability: PIs exhibit outstanding thermal stability, with heat deflection temperatures above 300°C and decomposition temperatures above 400°C. No softening and glass transition temperature can be noticed. SHort term use temperatures are up to 500°C. PI behaves like a thermoset with a linear property profile over the whole temperature range. 
  • Chemical Resistance: They are resistant to a wide range of chemicals, however they can be attacked by strong acids, and bases. PIs are hygroscopic and are not resistant towards hydrolysis. 
  • Mechanical Strength: PIs possess high tensile strength, flexural strength, and impact resistance.
  • Electrical Insulation: They are excellent electrical insulators with low dielectric constants and high dielectric strength.
  • Flame Retardancy: Many PIs are inherently flame-retardant.
Processing Methods
  • Solution Processing: Polyimide solutions can be cast into films, coated onto substrates, or spun into fibers.
  • Press-sintering: is used for making higher amounts of parts; otherwise cutting the part out of semi-finished shapes is done. 
  • Melt processing: thermoplastic Polyimides (TPIs) are injection moldable and extrusion prossable PIs. The major two commercially available are Ultem PEI (PI based on bisphenol A bisether-4-diphthalic anhy-dride [BEPA]) and Aurum TPI (PI based on Pyromellitic dianhydride [PMDA]). Aurum TPI has a Tg of 245°C. 
  • Copper enamel coating: Polyesterimides (PEsI) are used for wire enamel with excellent thermal properties. These kinds of  wires are widely used for compressors, washing machine motors, explosion-proof motors, dry transformers, and electric tools.
  • Additive Manufacturing: PIs are being explored for 3D printing applications, enabling the fabrication of intricate components.
Applications
  • Electronics: PIs are used in flexible printed circuit boards, high-temperature wire insulation, and semiconductor packaging (combination of high dielectric strength with low dissipation factors at various frequencies makes it a excellent insulation material)
  • Aerospace: They are employed in aircraft components, such as engine seals, heat shields, and structural reinforcements.
  • Automotive: PIs are used in engine components, electrical connectors, and thermal insulation.
  • Medical Devices: They are used in medical devices, catheters, and drug delivery systems.
  • Other Applications: PIs find applications in various industries, including energy storage, filtration, and protective coatings.

Trade Names and Economic Aspects
  • DuPont: Vespel® S, SP, SCP, and Kapton®
  • Mitsui: Aurum® TPI
The global polyimide market is growing steadily, driven by increasing demand from electronics, aerospace, and automotive industries. However, the high cost of raw materials and complex manufacturing processes can limit the widespread adoption of PIs.
In conclusion, polyimides are a versatile class of high-performance polymers with a wide range of applications. Their unique combination of properties, including exceptional thermal and chemical resistance, mechanical strength, and electrical insulation, makes them indispensable in many industries.

Polybenzimidazole (PBI) - the ultra high performance plastic which was developed in cooperation with NASA

Polybenzimidazole (PBI) is a high-performance polymer known for its exceptional thermal stability, chemical resistance, and mechanical properties. Its unique structure, consisting of a repeating benzimidazole unit, imparts these remarkable characteristics. It was developed in cooperation with NASA to have a lightweight, high heat, low friction, high chemical and radiation resistant polymer which can be used in space and aircraft applications. Nowadays the application field of  PBI is much broader and it is used in electric & electronic appliances too. Its unique structure, consisting of a repeating benzimidazole unit, imparts these remarkable characteristics. PBI has a glass transition point of 427°C and its high purity makes it ideal for cable insulation powder coatings, friction parts and housings.

Chemistry and Production

PBI is synthesized through a condensation polymerization reaction between a diamine, typically 3,3′-diaminobenzidine, and a dicarboxylic acid, such as terephthalic acid or isophthalic acid. The reaction involves the formation of amide bonds between the amine and carboxylic acid groups, leading to the formation of the PBI polymer chain.

The production process of PBI typically involves the following steps:
1. Monomer Preparation: The diamine and dicarboxylic acid monomers are purified to remove impurities that could affect the polymerization reaction.
2. Polymerization: The purified monomers are combined under controlled conditions, such as temperature, pressure, and solvent, to initiate the polymerization reaction.
3. Polymer Isolation: The resulting PBI polymer is isolated from the reaction mixture through techniques like filtration or precipitation.
4. Purification: The polymer is further purified to remove any residual monomers or byproducts.
5. Processing: The PBI polymer is processed into various forms, such as fibers, films, or composites, depending on the desired application.

Properties of PBI

PBI exhibits a range of properties that make it suitable for demanding applications:
  • Thermal Stability: PBI possesses excellent thermal stability with a glass transition temperature of 427°C, capable of withstanding temperatures up to 500°C without significant degradation. This property is attributed to the aromatic nature of the benzimidazole unit and the strong intermolecular forces between polymer chains. Figure 3 shows an overview of the PBI and PBI blends as well as PBI compounds with their glass transition temperature.  
Figure 3: Overview Tg of PBI, PBI blends, and PBI compounds [2].

  • Chemical Resistance: PBI is highly resistant to a variety of chemicals, including acids, bases, and solvents. This makes it ideal for applications in corrosive environments and applications where high temperatures and aggressive chemicals are combined present.
  • Mechanical Properties: PBI offers good mechanical properties, such as tensile strength, modulus, and toughness. Its mechanical performance can be further enhanced through reinforcement with fibers or other materials.
  • Wear resistance: PBI has low friction properties with a coefficient of friction of 0.4. The wear of PBI is low too.  The PBI grade Celazole TL-60 is a very good wear grade material, reaching a PV of 225,000 psi-ft/min at 200 fpm. 
  • Flame Resistance: PBI is inherently flame-resistant and can be used in applications where fire safety is a critical concern.
  • Barrier Properties: PBI can serve as an effective barrier to gases and vapors, making it useful in applications such as filtration and gas separation.
Processing Methods

PBI can be processed using various methods, depending on the desired form and properties:
  • Solution Processing: PBI can be dissolved in suitable solvents and processed into films, coatings, or fibers through techniques like casting, spinning, or printing.
  • Melt Processing: Although PBI has a high melting point, it can be processed using melt-spinning or melt-extrusion techniques under specific conditions. Also blending PBI with PEEK and PEKK enables processing in injection moulding and extrusion. 
  • Composite Processing: PBI can be combined with other materials to form composites, such as carbon fiber-reinforced PBI, which offer enhanced mechanical properties and thermal stability.
  • Compression moulding: can be used to make semi-finished shapes such as rods, films, sheets, and tubes. 
Applications of PBI
PBI's unique combination of properties makes it suitable for a wide range of applications, including:
  • High-Temperature Applications: PBI is used in components for aerospace isolations, aircraft engines, industrial furnaces, and heat exchangers due to its exceptional thermal stability.
  • Chemical Processing:  PBI is used in chemical processing equipment, such as filters, gaskets, and valves, due to its chemical resistance.
  • Protective Clothing: PBI is used in protective clothing for firefighters, industrial workers, and military personnel due to its flame resistance and thermal protection.
  • Gas Separation: PBI membranes are used in gas separation processes to selectively separate different gases.
  • Fuel Cells: PBI is used as a polymer electrolyte membrane in fuel cells, enabling efficient energy conversion.
Trade Names and Economic Aspects
There is only one major company producing the polymer PBI and offering it under various trade names, including:
  • PBI Polymer: Celazole(R)
  • PBI Advanced Materials (PBi-am; SATO Group): 7000 series
The market for PBI is relatively small compared to other polymers, but it is expected to grow due to increasing demand in niche applications. The economic aspects of PBI production and processing are influenced by factors such as the cost of raw materials, energy consumption, and market demand.

Conclusion
PBI is a high-performance polymer with exceptional properties that make it suitable for demanding applications. Its thermal stability, chemical resistance, and mechanical properties have led to its use in various industries, including aerospace, chemical processing, and protective equipment. As the demand for high-performance materials continues to grow, PBI is expected to play an increasingly important role in various technological advancements.

In the upcoming Part 2C we will discuss the Polyether high performance polymers such as PPE, PAEK, PEEK, and PEKK.

Thanks for reading & #findoutaboutplastics

Greetings, 
Literature: 
[1] https://pbipolymer.com/wp-content/uploads/2016/05/Polymer-Protects-Firefighters-Military-Civilians.pdf
[2] https://www.pbi-am.com/en/base-polymers/pbi
[3] Dynamic Mechanical Analysis of High Temperature Polymers, Ning Tian, Aixi Zhou, The University of North Carolina
[4] https://pbipolymer.com/wp-content/uploads/2021/07/Dynamic-Mechanical-Analysis-High-Temperature-Polymers.pdf
[5] https://pbipolymer.com/wp-content/uploads/2016/05/High_PV_Wear_Study_of_Six_High_Performance_Polymers.pdf
[6] https://www.pbi-am.com/en/base-polymers/pbi
[7] https://www.sabic.com/en/products/specialties/ultem-resin-family-of-high-heat-solutions/ultem-resin
[8] https://www.3dnatives.com/en/ultem-030820204/#!
[9] https://www.ensingerplastics.com/en/thermoplastic-materials/torlon-pai-polyamid-imide
[10] https://www.researchgate.net/publication/329955339_Thermoplastic_Polyimide_TPI
[11] https://pmc.ncbi.nlm.nih.gov/articles/PMC7240679/
[12] https://www.sciencedirect.com/science/article/abs/pii/S001191642400211X#:~:text=Nanofiltration%20(OSN).-,Abstract,temperatures%2C%20and%20low%20fuel%20crossover.

Thursday, 14 November 2024

New Online Tool - Calculate your Plastics CO2 equivalent (CO2e) Savings Potential

Hello and welcome to this post. I created an online calculator which allows you to quickly calculate the CO2 equivalent (CO2e) savings potential for your application.

Try the new tool out here

How to run the calculation

1) select you current material (if your material is not in the list, please reach out to me) 

2) select the alternative material 

3) enter the material usage per year in kg 

4) then your potential CO2 saving will be automatically calculated (cradle-to-gate)

If you want a more detailed calculation, please reach out to me under "contact me"

Example metal replacement (magnesium) vs Polyamide

Figure 1 shows the user interface of the calculator and the input values for the metal replacement example. As a result, changing from Magnesium to Polyamide 6.6 has a CO2e saving potential of 47%.

Figure 1: Example of the potential CO2e savings when switching from Magnesium to PA 6.6.



Thanks for reading and #findoutaboutplastics

Greetings,

 


Wednesday, 6 November 2024

Design Properties for Engineers: Dynamic Mechanical Analysis (DMA) of Ultra Performance Polymers (PBI and PBI blends)

Hello and welcome to a new post on design properties for engineers. In today’s post we discuss the storage modulus E’ measured by DMA of the ultra performance polymer Polybenzimidazole (PBI). Check out my other post on DMA of high performance polymers here. DMA is an essential tool for polymer material selection, allowing you to immediately capture the mechanical behaviour over a wide temperature range. 

What is Polybenzimidazole (PBI)?

PBI is the ultra high performance plastic which was developed in cooperation with NASA to have a lightweight, high heat, low friction, high chemical and radiation resistant polymer which can be used in space and aircraft applications. Nowadays the application field of  PBI is much broader and it is used in electric & electronic appliances too. Its unique structure, consisting of a repeating benzimidazole unit, imparts these remarkable characteristics. PBI has a glass transition point of 427°C and its high purity makes it ideal for cable insulation powder coatings, friction parts and housings. 

Storage Modulus E’ of PBI and PBI-blends

Figure 1 shows the storage modulus vs. temperature behaviour of PBI, PBI-PEEK blend, PAI, and PEI. They all show a significant drop in modulus in the glass transition region, expect of PBI. Before reaching the Tg, the neat PBI polymer still has a storage modulus of 3 GPa, where else the other presented polymers have already reached the zero level at this temperature. Blending PBI with PEEK makes it easier for melt processing and still up to 200°C a high level of modulus can be achieved. Among the amorphous high performance polymers, PAI has with 275 °C the highest glass transition temperature. A continuous use temperature of 260°C is feasible. PAI is melt processable in an injection moulding machine and needs an annealing step after moulding. 

Figure 1: Storage modulus E' of PBI and PBI blends [1]

Thanks for reading and #findoutaboutplastics

Greetings

Herwig Juster
Literature:

Sunday, 27 October 2024

My Guest-Contribution in "Sustainable medical technology: Rethinking plastics in medical technology" by BIOPRO Baden-Württemberg GmbH

Hello and welcome to a new blog post. Today I show you an article written by Dr. Ruth Menßen-Franz from the BIOPRO Baden-Württemberg GmbH to which I have contributed to as a guest. 

Plastics play a vital role in medical technology and medical device applications. In this article we discuss how to create more environmentally friendly plastic products in the future, using new bioplastics, best-practices in part design, and new ways of recycling. 

Thanks for reading & #findoutaboutplastics

Greetings, 

Herwig 







Friday, 25 October 2024

Rule of Thumb in Polymer Injection Moulding: Fast Estimation of Cooling Time

Hello and welcome to another Rule of Thumb post. Today we discuss how to fast estimate the cooling time in injection moulding. 

Main influencing factor of the cooling time is the wall thickness, since it the wall thickness is included squarely in the cooling time calculation. Another factor is the tool temperature. For example, a 10°C increase of tool temperature will lead to a 30% elongation in cooling time. Increasing the melt temperature will lead only to a 3% increase in cooling time. 

Equation 1 shows the simplified cooling time calculation which can be used for a fast assessment (it is still recommend to calculate the cooling time with a more detailed equation whenever possible). We need to have the maximum wall thickness of your part and a multiplication factor between 1.5 and 2 (sometimes also higher e.g. 2.5 for PARA). 

Equation 1: Estimating the cooling time in injection moulding [1].

Check out the video on this topic on my YouTube channel too: 


More polymer engineering Rule of Thumb posts can be found under "start here".

Thanks for reading and #findoutaboutplastics

Greetings

Herwig Juster
Literature:
[1] https://www.emsgrivory.com/fileadmin/user_upload/EMS-GRIVORY/documents/Brochures/English/5017_en_Long-fibre-reinforced-polyamides.pdf
[2] https://www.findoutaboutplastics.com/2018/04/plastics-part-design-10-holy-design.html

Sunday, 6 October 2024

Rule of Thumb in Polymer Engineering: How Economy of Scale Can Lower Costs

 Hello and welcome to this new Rule of Thumb post. More Rule of Thumbs can be found in my section "Start here"

Economy of Scale: A Brief Explanation

Economy of scale refers to the cost advantage that arises when a company increases its production level. In simpler terms, the more a company produces, the lower the cost per unit becomes. This is because fixed costs (like rent, machinery, and salaries) are spread out over a larger number of units.

How Economy of Scale Can Lower Costs

  • Increased Production Efficiency: Larger production runs often lead to more efficient processes, reducing waste and improving productivity (each time the cumulative production of a given product gets doubled, costs can be reduced in range of 15%).
  • Bargaining Power with Suppliers: Larger companies can negotiate better deals with suppliers due to their increased purchasing volume.
  • Specialized Equipment: Investing in specialized equipment can significantly reduce production costs for large-scale operations.
  • Risk Diversification: Larger companies can better absorb market fluctuations and other risks.
Example: Plastic Injection Moulding

In plastic injection molding, economy of scale is a significant factor in determining production costs. A company that produces a large number of plastic parts can benefit from:

  • Specialized Moulding Machines: High-volume production justifies the investment in advanced, efficient moulding machines that can produce parts faster and with less waste.
  • Optimized Production Processes: With experience and scale, companies can fine-tune their production processes to minimize setup time, reduce cycle times, and improve quality. Using a Lang-factor of 0.75 we can reach a cost reduction of 30% when doubling the production amount (Figure 1).  
  • Bulk Material Purchasing: Larger quantities of plastic resin can often be purchased at a discounted rate, reducing material costs.
  • Efficient Manufacturing Layout: A well-designed manufacturing layout can streamline production flow, minimizing material handling and reducing overhead costs.
Figure 1: xample economy of scale in plastic injection moulding - doubling the production amount leads to a 30% cost reduction. 


By leveraging economy of scale, plastic injection moulding companies can significantly lower their production costs, making their products more competitive in the marketplace. 

Thanks for reading and #findoutaboutplastics

Greetings

Herwig Juster
Literature:
[1] https://www.stratxsimulations.com/latest_materials_circular_markstrat/NetHelp/enu/Handbook-SM-B2C-DG/DocToHelpOutput/NetHelp/index.html#!Documents/productivitygains.htm
[2] https://www.voestalpine.com/highperformancemetals/en/blogposts/how-to-increase-efficiency-and-productivity-in-plastic-injection-molding/#


Friday, 4 October 2024

Polymer Selection Funnel Example - Smartphone Front Bezel (Consumer Electronics Material Selection)

Hello and welcome to another polymer material selection example for which we use the POMS-Funnel Method (in detail explained here and in this video). Today’s mission is to select the optimal polymer for Liquid Crystal Display (LCD) bezel used in smartphones. 

Figure 1 presents the four different stages of the material selection funnel as well as the tools we can use to facilitate the selection. We can use this as a guideline throughout the selection journey. 

Figure 1: Polymer Selection Funnel - overview of the four different funnel stages and tools.

POMS-Funnel Method: 

Funnel stage 1: Material selection factors

In the first Funnel stage we focus on gathering and understanding all the requirements of the LCD bezel for smartphones (Figure 2).  
Figure 2: Overview of a LCD front bezel used in the iPhone 14 Plus. Aim of the first funnel step is to lay out the requirements.


Covering effectively the product requirements, a combination of functionality questions and selection factor questions can support you to achieve this. First we have to ask some questions on the functionality of the part. 

Following questions can help us with this assessment:
-What are the performance requirements (structural, etc.)?
-Do you want to combine multiple parts or functions?
-What will be the structural load of the part (static, dynamic, cycling, impact, etc.)?
-What will be the environmental impact on the part (chemical, temperature, time)?
-What is the expected lifetime of the product?

After answering the functionality questions, we continue with the, in my point of view,  six essential questions on material selection factors (6 What's).

A more detailed list can be found here (incl. download): Material Selection Requirements Checklist

1. What is the service environment of your part?
2. What are the regulatory requirements?
3. What types of load at which service temperature and time need to be fulfilled?
4. What other things such as wear and friction, electrical properties such as CTI, electrical breakdown strength, aesthetics and colour (relevant for application with food contact, and toys), and more, need to be considered?
5. What is the processing and fabrication method?
6. What are the economic and commercial considerations?

In general, LCD bezels, the outer frame that surrounds the LCD screen in smartphones, play a crucial role in both aesthetics and functionality. The materials used for these bezels must meet specific requirements to ensure optimal performance and durability.

Key Requirements for LCD Bezel Materials:

Aesthetics:
-Color: The bezel's color should complement the overall design of the smartphone and align with current trends.
-Finish: The finish can range from matte to glossy, depending on the desired aesthetic.
Texture: The texture can be smooth, textured, or even embossed to create a unique feel.

Durability:
-Scratch Resistance: The material should be resistant to scratches, as smartphones are often carried in pockets or bags and may come into contact with other objects.
-Impact Resistance: The bezel should be able to withstand minor impacts without cracking or shattering.
-Strength: Thin wall frame need to have high strength levels too, together with dimensional stability.
-Wear and Tear: The material should be durable enough to resist wear and tear over time.

Functionality:
-Signal Transmission: The bezel material should not interfere with wireless signal transmission, such as Wi-Fi or cellular data. The material should have a dielectric constant of 3.5.
-Display Visibility: The bezel should not obstruct the viewing angle of the LCD screen.
-Thermal Conductivity: The material should have good thermal conductivity to help dissipate heat generated by the smartphone's internal components.
-Processability: High flow material enabling to fill thin wall thickness; possibility for  IML/IMD “In-Mold Labelling/Decoration”,

Cost:
-Affordability: The material should be cost-effective to ensure that the smartphone remains competitive in the market.

Capturing all requirements and project details can be done by using the requirement worksheet and Table 1 shows the outcome. 
Table 1: Overview of requirements for the LCD front bezel using the requirement worksheet. 

Funnel stage 2: Decision on thermoplastic or thermoset

With the LCD bezel requirements, together with the understanding of the differences of thermoplastics (amorphous and semi-crystalline) and thermosets we can screen the databases and material suppliers for suitable material candidates.  

There are reliable database such as Campus and Omnexus and I created dashboards to support this step too: 



All dashboards can be found also here.

Deciding between the thermoplastic or thermoset route is the first step. In our case, thermoplastics offer many advantages for this application, especially impact performance at low and high temperatures and injection moulding in the range of million parts per year in an economical way. Reviewing the bezel requirements, both amorphous and semi-crystalline materials are feasible. 

After the material screening, I pre-selected the following materials (Table 2): 
  • Lexan® HFD4472 (PC-CoPo-GF20)
  • Kalix 2545 (PA 6.10-GF45; bio-sourced)
  • TORAYCON™ 7151G-F03 (PBT+SAN-GF30)
  • Zytel® HTN52G35HSL (PPA-GF35; PA6T/66-GF35)
Table 2: Overview preselected grades and their commercial suppliers.

Funnel stage 3: Selection discussion with worksheet (qualitative matrix analysis)

The third funnel stage represents a core element in the whole material selection funnel. It is a detailed selection discussion with a worksheet. I call it the decision matrix analysis and it ranks all of the pre-selected polymers. The decision matrix analysis consists of five steps. The base calculation principle is a scoring of each of the pre-selected materials for each of the material selection factors. In the end we add up all weighted scores for each material. The materials with the highest score are most suitable for selection and further investigation in the fourth stage.

How to start the qualitative matrix analysis?
I developed an online tool in order to facilitate this step here (Polymer Material Selector V1.1). As an alternative, you can reach out to me and I will provide you with an excel version of it. I only considered the must-have requirements.

In Table 3 the outcome of the qualitative matrix analysis is shown. PA 6.10-GF45 scored the highest number of points (score: 132 points), followed by PC-CoPo-GF20 (score: 98 points) and PBT+SAN-GF30 (score: 97 points) and PPA-GF35 (score: 93). All four materials should be validated in the Funnel stage 4 since there are important tests such as the antenna performance tests, falling and rolling test, and anti-stain test. 

Table 3: Results of the qualitative matrix analysis.

Funnel stage 4: Testing, selection of material and vendor

In the final step of the POMS-method we perform the antenna performance tests, falling and rolling test, and anti-stain test, as well as build first prototypes (with the support of CAE - filling simulation). Once all the test results are available, the final material decision can be done. 

For the premium consumer segment of smartphones, PA6.10-GF45 and PC-CoPo-GF20 are a good choice and if surface aspects are not the most important criteria, the remaining two materials (PPA and PBT+SAN) can be considered too. 

Conclusions
In this example we applied the POMS-method  for selecting the optimal thermoplastic grade for a LCD bezel used in smartphones. It is a systematic approach with a resin-agnostic view allowing to consider different material choices and document them for a later review and optimization. 

More polymer material selection examples using the funnel approach can be found here:

Thanks for reading and #findoutaboutplastics

Greetings

Herwig Juster
Literature:
1] https://www.sunsky-online.com/de/p/EDA006095301/For-iPhone-15-Plus-Front-LCD-Screen-Bezel-Frame.htm
[2] https://www.polymerio.com/tds-pds/pbt-compound-toray-toraycon-7151g-f03-b--tds-pds
[3] https://materials.celanese.com/de/products/datasheet/SI/Zytel%20HTN52G35HSL%20BK083
[4] https://www.syensqo.com/en/brands/kalix-hppa
[5] https://www.sabic.com/en/products/specialties/lnp-compounds-and-pc-copolymer-resins/lexan-copolymer
[6] https://www.plastics.toray/de/products/toraycon/pbt_003.html