2025 - It's A Wrap - Seasons Greetings & Outlook 2026

Dear Community,

As 2025 draws to a close, I want to extend my heartfelt gratitude to all my newsletter and blog readers, followers, supporters, and colleagues. Happy Holidays! May you enjoy a safe and relaxing season surrounded by friends and family.

Season Greetings 2025 - Thank you to all my readers, followers, and supporters. Picture made with Nano Banana Pro

Reflecting on 2025: A Year of Growth and Innovation

What a year it has been! Our Pumping Plastics Newsletter and the Find Out About Plastics community continued to grow, fueled by your engagement and curiosity. I had the privilege of conducting three expert interviews with Technoform, exploring topics such as unlocking the potential of hybrid extrusion, the development of a product carbon footprint calculator for plastic profiles, and pioneering pultrusion profiles with extreme strength using endless glass fiber.

In 2025, I published 45 blog posts—soon to be available as the book "Pumping Plastics 2025" at the start of 2026. Each post’s highlights, lessons learned, and key takeaways will be included in the end for your reference. I’m also excited to share that we crossed the 1,000-subscriber mark on my YouTube channel!

This year saw the launch of several new tools and platforms:

• The Aliphatic Polyketone (PK) Grade Screening App
• The Polyarylamide Property Explorer
• PlastCalcs.com—a comprehensive polymer engineering calculation platform, enabling you to make all your calculations in one place.

On a personal note, I achieved ISO/IEC 17024 certification as an expert witness for plastics and plastic part analysis—more on this in 2026!

Looking Ahead: 2026 and Beyond

The future of plastics remains dynamic and promising. Global plastics use is projected to rise from 464 million tons in 2020 to 884 million tons by 2050, with accumulated stocks reaching 4,725 million tons [1]. The plastics part industry, especially in injection molding, is set to grow from $554 billion in 2025 to nearly $900 billion by 2032.

Artificial Intelligence is rapidly transforming the plastics value chain—from polymer development to circularity. In 2026, we’ll see AI move from research novelty to industrial deployment, shifting from data generation to data-driven engineering decisions, and providing a real competitive edge through AI-integrated workflows.

However, the chemical and plastics industries are not without challenges. The current economic downcycle, driven in part by overcapacity in China, reminds us that Europe’s greatest strength lies in innovation—not just in raw material costs, but in creating new, value-added products. Our industry’s resilience and capacity for reinvention will keep us moving forward.

Key Messages for the Chemical and Plastics Industry

• Embrace Humility and Continuous Learning: Success requires openness to new ideas, feedback, and lifelong learning.
• Value Teamwork and Collaboration: Achievements are built on strong, diverse teams and cross-functional partnerships.
• Adaptability is Essential: Rapid changes in technology, regulation, and markets demand flexibility and proactive engagement—especially with digital and sustainability trends.
• Practice Responsible Leadership: Empower your teams, communicate openly, and focus on ethical, long-term value creation.

What’s Next?

My blog will continue to deliver insights on polymer material selection, plastics failure analysis, and the growing role of AI and machine learning in polymer engineering. Expect new content on medical and defense applications—such as polymers for protective equipment—and expanded calculation tools on PlastCalcs.com, especially for injection molding and material selection.

Thank you all for being part of this ever-evolving plastics community. Remember: Plastics are part of the solution, not the problem.

Wishing you joy, rest, and happy holidays—and a fantastic start to 2026!

Greetings & #findoutaboutplastics

Herwig 

Epilogue:

Here are concise key highlights or lessons learned from each of my 2025 blog posts:

January 2025

1. Injection Moulding of Polyarylamides

Key takeaway: Successful injection moulding of polyarylamides requires careful control of processing parameters to optimize part quality and performance.

2. 10 Key Considerations for Selecting Plastics for Injection Moulding

Highlight: Material selection for injection moulding should balance mechanical, thermal, and chemical properties with cost and manufacturability.

3. Rule of Thumb: Water Lilies and Polymer Growth

Lesson: Understanding exponential growth in polymers, much like water lilies, helps anticipate material behavior and process scaling.

February 2025 

4. Injection Moulding of Polyphenylene Sulfide (PPS)

Takeaway: PPS offers excellent chemical resistance and dimensional stability, but requires precise temperature and moisture control during moulding.

5. Polymer Selection Funnel Example: Base Plate

Highlight: Using a structured selection funnel streamlines the process of identifying the best polymer for specific applications like base plates.

6. Plastics Industry: How to Kickstart Your Career

Lesson: Building a successful plastics career involves continuous learning, networking, and staying updated on industry trends.

March 2025 

7. Metal Replacement with Plastics: 5-Step Guide

Key takeaway: A systematic approach—evaluating requirements, material selection, design adaptation, prototyping, and testing—ensures effective metal-to-plastic conversion.

8. Polycaprolactone (PCL): A Versatile Polymer

Highlight: PCL stands out for its biodegradability and versatility in medical and industrial applications.

9. Polyarylamide (Para-MXD6) and Recycling

Lesson: Para-MXD6 offers recyclability advantages, supporting sustainable practices in high-performance applications.

10. Become a Master in Polymer Material Selection

Takeaway: Mastery in polymer selection comes from understanding application needs, material properties, and processing constraints.

April 2025 

11. The Path to Polymer Selection Mastery

Highlight: Achieving expertise in polymer selection requires a blend of technical knowledge and practical experience.

12. More Than Just Profiles: Unlocking Extrusion Potential

Lesson: Extrusion technology offers diverse possibilities beyond simple profiles, enabling innovative product designs.

13. Mastering Melt: Your Guide to Shear Rate in Plastics

Takeaway: Controlling shear rate during processing is crucial for optimizing melt flow and final part properties.

14.Nature is Built on 5 Polymers: Modern Lessons

Highlight: Learning from nature’s five foundational polymers can inspire sustainable and efficient material solutions.

May 2025 

15. Glass Fiber Filled PET vs. PBT: Choosing the Right Material

Lesson: Comparing glass fiber-filled PET and PBT helps engineers select the optimal material based on performance and application needs.

16. When Childhood Crumbles: Understanding Polymer Aging

Takeaway: Polymer aging affects product durability, emphasizing the importance of material selection and stabilization.

17. PET Grade Selection for Diverse Applications

Highlight: Selecting the right PET grade ensures product performance across various industries and applications.

18. 5 Benefits of Incorporating Life Cycle Assessment (LCA)

Lesson: Integrating LCA into product development supports sustainability and informed decision-making.

19. 4 Tips for Effective Polymer Material Comparison

Takeaway: Comparing polymers effectively involves considering mechanical, thermal, chemical, and economic factors.

June 2025 

20. Polymers and the Lindy Effect: Rule of Thumb

Highlight: The Lindy Effect suggests that polymers with a long history of use are likely to remain relevant and reliable.

21. High-Performance Thermoplastic Selection

Lesson: Selecting high-performance thermoplastics requires balancing advanced properties with processing and cost considerations.

22. The Sticky Truth About Gluing Plastics

Takeaway: Successful adhesive bonding of plastics depends on surface preparation, adhesive choice, and understanding material compatibility.

23. Design Properties for Engineers: Thermal Expansion

Highlight: Accounting for thermal expansion in design prevents warping and ensures dimensional stability in plastic parts.

July 2025 

24. Discover the Future of Polyketone Selection

Lesson: Polyketones offer promising properties for future applications, combining chemical resistance with mechanical strength.

25. Choosing the Right Polymer: Why Cheapest Isn’t Always Best

Takeaway: Selecting polymers based solely on cost can compromise performance and long-term value.

26. Plastic Part Failure Analysis Using Microscopy

Highlight: Microscopy is a powerful tool for diagnosing plastic part failures and guiding corrective actions.

27. The Melting Point Mystery: Identifying Plastics

Lesson: Melting point analysis is a key technique for identifying unknown plastic materials.

August 2025 

28. Design-to-Cost (DTC) in Plastic Part Development

Takeaway: Implementing DTC strategies helps balance performance and cost-effectiveness in plastic part design.

29. How Many Cavities Should You Choose for Your Mold?

Highlight: Determining the optimal number of mold cavities involves evaluating production volume, cycle time, and cost.

September 2025 

30. Designers & Engineers: Tired of Warped Parts?

Lesson: Addressing warpage in plastic parts requires attention to material selection, part design, and processing conditions.

31. Mastering Injection Molding Tools for Success

Takeaway: Proper tool selection and maintenance are critical for achieving consistent quality in injection molding.

32. Turning Product Requirements into Polymer Solutions

Highlight: Translating product requirements into material choices ensures functional and manufacturable plastic components.

33. How Additives Make or Break Plastics

Lesson: Additives significantly influence plastic properties, processing, and end-use performance.

October 2025 

34. Stories from the Plastics Industry Triangle

Takeaway: Real-world industry stories illustrate the interconnectedness of material, process, and design decisions.

35. Don’t Mix Maximum with Optimum: Plastic Design

Highlight: Optimal design balances performance and manufacturability, rather than pushing every parameter to its maximum.

36. My Highlights from K Fair 2025: Global Plastics Trends

Lesson: K Fair 2025 showcased innovations in sustainability, digitalization, and advanced materials in the plastics industry.

37. Say Goodbye to PTFE: Discover UHMW-PE

Takeaway: UHMW-PE offers a viable alternative to PTFE, with comparable properties and additional processing benefits.

November 2025 

38. Evaluating High-Temperature Performance of Plastics

Highlight: Assessing high-temperature performance is essential for selecting plastics in demanding applications.

39. Plastic Part Failure Analysis Example

Lesson: Detailed failure analysis provides insights for improving design, material selection, and processing.

40. Polycarbonate Market Review 2025

Takeaway: The 2025 polycarbonate market is shaped by trends in sustainability, demand, and technological advancements.

41. Wombat: Not Just an Animal—A Lesson for Plastics

Highlight: Drawing inspiration from nature, like the wombat, can lead to innovative solutions in plastics engineering.

42. Ratio Project’s Story: Beyond Plastic

Lesson: The Ratio Project demonstrates the importance of holistic approaches in sustainable plastics development.

December 2025 

43. Cleaning of Injection Molding Tools I

Takeaway: Regular and effective cleaning of injection molding tools extends tool life and ensures product quality.

44. Practical Bio-ABS Selection Guide

Highlight: Bio-ABS offers a sustainable alternative to conventional ABS, with selection guided by application requirements.

45. How to Mark Plastic Parts with Recycled Content

Lesson: Proper marking of recycled content in plastic parts supports transparency and compliance with sustainability standards.

Literature: 

[1] https://www.sciencedirect.com/science/article/pii/S2352550924002823

Cleaning of Injection Molding Tools I Dry Ice Blasting I Processing Hack

Hello and welcome to a new processing hack blog post, in particular on how to clean you injection mold in an optimal way. 

Dry ice cleaning (Dry ice blasting) is an efficient, non-abrasive method for cleaning injection molding tools that allows for faster cleaning cycles and reduced production downtime. The process involves propelling solid carbon dioxide (CO2) pellets at a high speed toward the mold surface, which removes contaminants through a combination of kinetic energy, thermal shock, and gas expansion (sublimation). 

Key Benefits

Minimal Downtime: Molds can be cleaned in-place (in-situ) and at their operating temperature, eliminating the need for cooling, disassembly, reassembly, and reheating. This can reduce cleaning times by up to 75% or more.

Non-Abrasive: Dry ice is a soft medium that sublimates into a gas upon impact, so it does not damage or erode delicate mold surfaces, intricate details, or critical tolerances (Class A-D finishes). This helps prolong the lifespan of valuable tooling.

No Secondary Waste: Because the dry ice turns directly into CO2 gas, there is no water, chemicals, or blasting media residue left behind. The only cleanup required is the removed contaminant itself, which can often be simply swept or vacuumed away.

Improved Product Quality: Cleaning molds more frequently and effectively ensures consistent venting and cavity shape, which helps prevent defects like flash, short shots, and splay, leading to lower scrap rates and higher part quality.

Environmentally Friendly and Safe: The process reduces or eliminates the need for harsh chemical solvents, improving workplace safety and environmental compliance. The CO2 used is often a reclaimed byproduct from other industrial processes.

Cleans Complex Geometries: The process can reach into hard-to-access areas, crevices, and fine vents that are difficult to clean with manual methods or other media. 

Apart from dry ice cleaning, there are three more cleaning technologies which can be utilized. I have listed them in Table 1. 

Table 1: Comparison of injection tool cleaning technologies. 

How It Works

The cleaning action is based on three main principles: 

• Kinetic Effect: High-velocity dry ice pellets physically impact and dislodge contaminants.
• Thermal Shock: The extreme cold temperature of the dry ice (-78.5°C or -109.3°F) causes the surface residue to shrink and become brittle, breaking its bond with the warmer mold substrate.
• Gas Expansion: Upon impact, the dry ice pellets instantly sublimate (turn into gas). This rapid expansion of CO2 volume creates microscopic "mini-explosions" that lift and carry the dirt particles away from the surface. 

Implementation

Manufacturers can either invest in their own portable dry ice blasting equipment (machines and a supply of dry ice and compressed air are needed) or utilize third-party contract cleaning services. Leading equipment manufacturers like Cold Jet offer a range of machines and accessories tailored for delicate to more aggressive cleaning applications. 

Example Cleaning Methods for PPS-GF / PPS-GF+MD Mold Deposits

Cleaning mold deposits from a Polyphenylene Sulfide (PPS) reinforced with glass fiber (GF) and mineral (MD) and/or impact modification often involves a combination of chemical and physical methods. The high service temperature and chemical resistance of PPS require specific cleaning considerations. 

• Chemical Cleaners (During Production): Specific solvent-based, fast-evaporating mold cleaners are effective for use while the mold is still in the injection machine. 
• Apply the cleaner to the top of the open mold and let gravity help the product flow down, flushing away contaminants. These cleaners work by dissolving greases, oils, and gas deposits, which are common byproducts of the molding process. 
• Products like Slide Resin Remover are used during production to "mold off" stubborn deposits in subsequent cycles.
• Physical Assistance: Chemical cleaning is often best when combined with a physical cleaning action.
• For light deposits, a clean, lint-free shop rag can be used for wiping.
• For strongly attached or heavy deposits, use a soft, non-damaging tool like a bamboo, copper, or brass spatula or brush to avoid scratching the mold surface. Metal abrasives can also be used with caution.
• Offline Cleaning (Tool Room): When the mold is removed for thorough cleaning, stronger, fast-evaporating cleaners (often hydrocarbons and naphthas) may be used to dissolve resins and greases. These can be followed by a mold polish/cleaning compound with mild abrasives for a final sheen.
• Advanced Method (Dry Ice Blasting): As explained above, dry ice blasting is a highly effective method that can remove deposits without disassembling the mold from the machine. It works by freezing and air-blasting the contamination off the surface. 

Best Practices for cleaning PPS-GF / PPS-GF+MD mold deposits

• Frequency: Clean frequently. Small amounts of deposits are easy to wipe away; once they accumulate, they can become corrosive and require more aggressive measures.
• Post-Cleaning Protection: Because PPS outgassing can be acidic, always follow cleaning with a rust preventive if the mold will be idle for more than a few hours.
• Solvent Selection: Ensure the cleaner is compatible with your mold temperature. High-evaporation solvents (like hydrocarbons) are best for offline cleaning, while slow-evaporating ones provide better "soak time" for thick deposits.

More processing tips can be found here: Optimizing your injection moulding production – my 5+ How’s

Thanks for reading & #findoutaboutplastics

Greetings,

Herwig 

Literature: 

[1] https://blog.coldjet.com/dry-ice-blasting-vs.-alternative-cleaning-methods

[2] https://www.findoutaboutplastics.com/2016/12/optimizing-your-injection-moulding.html

Practical Bio ABS Selection Guide Including Example (Housing of CHIMEI Ballpoint Pen)

Hello and welcome to a new blog post on selecting bio-based ABS materials for consumer applications. In the first section, I provide you with an overview on what to consider when selecting a bio-based material in general, and in the second section I discuss the housing of a ballpoint pen made out of bio-based ABS from CHIMEI.  

Selection of bio-based ABS plastic

When selecting a bio-based ABS plastic, consider its performance properties like impact resistance and temperature stability, its processability, and its end-of-life options, such as biodegradability or recyclability. You should also evaluate factors like cost, regulatory compliance (e.g., food contact), and sustainability claims using a method like a life cycle assessment (LCA) to ensure it meets your specific needs and environmental goals. 

Performance and functionality

• Mechanical Properties: Compare the bio-based plastic's tensile strength, impact toughness, and ductility to conventional ABS to ensure it can withstand the application's stress.
• Thermal Properties: Evaluate its operating temperature range, heat deflection temperature, and coefficient of thermal expansion (CTE) to prevent warping and ensure it's suitable for the intended environment.
• Chemical Resistance: Determine if the bio-based plastic is resistant to the chemicals it will be exposed to. Some are sensitive to certain solvents, acids, or alkalis. 

Processability

• Processing Methods: Check if the material is compatible with existing processing equipment, such as injection molding or 3D printing, and has a controllable melt behavior to reduce issues like warpage.
• Additives: Be aware that additives, like silica, can affect properties. For instance, silica can improve strength but may increase brittleness.
• Melt and Glass Transition Temperatures: Understand the material's specific temperatures for extrusion or printing, which will be different from fossil-based ABS. 

Sustainability and end-of-life

• Bio-based content: Not all "bio-based" plastics are 100% derived from renewable sources. The bio-based content is an important metric, and certifications may require a minimum percentage to be considered eco-friendly.
• Biodegradability: Bio-based does not automatically mean biodegradable. Verify if the material is compostable or biodegradable and what the specific requirements are for degradation.
• Recyclability: Confirm if the material can be recycled and what infrastructure exists for recycling it.
• Life Cycle Assessment (LCA): Use LCA to quantitatively compare the environmental impact of different bio-based options against each other and against traditional plastics across their full life cycle. 
• End-of-life options: Bio-based does not mean biodegradable. Clarify the appropriate end-of-life pathway, which may include industrial recycling or composting, and ensure the necessary infrastructure exists in your region.
• Sustainable sourcing: Investigate the sourcing of the bio-based feedstock to avoid competition with food and water resources or negative impacts on land use and biodiversity.
• Supplier transparency: Work with suppliers and distributors that provide clear, detailed documentation on the formulation, sourcing, and environmental standards (like ISO 14001, REACH, or RoHS). 

Business and market considerations

• Cost: Bio-based ABS is often more expensive than traditional ABS, though costs are expected to decrease as technology advances and production scales. Weigh the potentially higher material cost against the long-term value, including sustainability goals and customer demand.
• Supplier reliability: Ensure the supplier can provide a consistent and reliable supply of material. Factors like agricultural yields and refining efficiencies can affect the availability and price of bio-based feedstocks.
• Regulatory compliance: Confirm that the material meets all relevant regulations and standards for your application, such as FDA compliance for food contact or specific certifications for the automotive or electronics industries.
• Consumer perception: Consider how your customers will perceive the new material. Use certifications and clear communication to market the product's environmental benefits accurately and transparently.

Industry example - CHIMEI Ecologue™ Bio ABS Material for Ballpoint Pen Housing

Wen-long Hsu (許文龍) founded CHIMEI Corporation, a Taiwanese company that became a leading producer of ABS (Acrylonitrile Butadiene Styrene) plastic, a versatile and durable material used in many products. Mr. Hsu was known for his business acumen and his commitment to social responsibility, which included prioritizing the welfare of his employees and funding the creation of the CHIMEI Museum. The history of CHIMEI ABS is therefore the story of a successful business built by Mr. Hsu Wen-long on a foundation of ethical business practices and a vision for social contribution. 

At K Fair 2025 I was introduced to Mr. Yu-Ching Yang, Director of Sales Division from CHIMEI and he gave me a special gift: a ballpoint pen made out of bio-based ABS (Figure 1). 

What makes it so special? 

Figure 1: Ballpoint pen housing made out of Ecologue™ Bio ABS.

It is made out of their Ecologue™ Bio ABS. Instead of fossil based feedstock, Ecologue™ Bio ABS uses bio-attributed feedstock, allowing for product carbon footprint (PCF) reduction of 122% compared to fossil based ABS (Figure 2). Such an impressive reduction is achieved by using biomass residues or wastes as the feedstock and enhancing circularity.

Figure 2: Emission comparison of fossil-based ABS vs. CHIMEI bio-based ABS.

Key Takeaways for Selecting Bio-Based ABS Plastics

Performance Must Match Application Needs:

When considering bio-based ABS, ensure its mechanical, thermal, and chemical properties are suitable for your specific application. Not all bio-based alternatives perform identically to conventional ABS, so thorough testing and comparison are essential.

Sustainability Claims Require Scrutiny:

“Bio-based” does not always mean biodegradable or fully renewable. Always verify the actual bio-based content, recyclability, and end-of-life options. Use tools like Life Cycle Assessment (LCA) to objectively evaluate environmental impact and ensure the chosen material aligns with your sustainability goals.

Business and Compliance Factors Matter:

Evaluate the cost, supplier reliability, and regulatory compliance of bio-based ABS. Transparent documentation and certifications are crucial for both market acceptance and meeting industry standards.

All over, keep a holistic approach—balancing performance, sustainability, and business needs—when selecting bio-based ABS plastics next time.

Thank you for reading & #findoutaboutplastics

Greetings, 

Herwig 

Literature: 

[1] https://www.chimeicorp.com/en-US?page=article&id=641137a3909e10048d14afca

[2] https://salesplastics.com/abs-plastic/#:~:text=ABS%20maintains%20stability%20across%20a,and%20thermal%20degradation%20during%20processing.

[3] https://www.omya.com/en/omya-performance-polymer-distribution

How to Mark Plastic Parts with Recycled Content: A Quick Guide to ISO 1043 & ISO 11469

Hello and welcome to a new blog post on plastic part marking. As the plastics industry moves toward a circular economy, clear and standardized part marking is more important than ever—especially when using recycled materials. ISO 1043 and ISO 11469 provide the global framework for material identification and marking, helping manufacturers, recyclers, and end-users quickly recognize what’s in a plastic part.

Here’s how to apply these standards when your part contains recycled material (Figure 1):

1. Basic Material Identification

• Use angle brackets to indicate the polymer type.
  • Example: >ABS< for acrylonitrile-butadiene-styrene.

2. Declaring Recycled Content

• If your part includes recycled material, you have several marking options:
  • No specific claim:
    >ABS<
    (Use this when you don’t want to declare recycled content.)
  • General claim of recycled content:
    >ABS(REC)<
    (Use this to indicate the presence of recyclate, without specifying the amount.)
  • Specific claim with minimum percentage:
    >ABS(RECx)<
    (Replace “x” with the minimum percentage by mass. For example, >ABS(REC30)< means at least 30% recycled content.)

3. Marking Polymer Blends and Alloys

• For blends, list the main polymer first, followed by the secondary polymer:
  • Example: >PC+ABS< for a polycarbonate and ABS alloy.
• To declare recycled content in a blend:
  • Example: >PC+ABS(REC30)< for a blend with at least 30% recycled content.

Figure 1: Applying ISO 1043 for plastic part marking when containing recycled materials.

Why does this matter?
Consistent and transparent marking supports efficient recycling, traceability, and compliance with sustainability goals. It also helps customers and recyclers make informed decisions—boosting the value of recycled plastics in the marketplace.

In summary:
When designing plastic parts with recycled content, follow ISO 1043 and ISO 11469 for clear, standardized marking. It’s a small step that makes a big difference for the circular plastics economy!

Check out my detailed guide on ISO 1043 plastic part marking codes here.

Thanks for reading & #findoutaboutplastics

Greetings,

Herwig Juster

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Literature: 

[1] https://www.findoutaboutplastics.com/2020/12/plastic-part-marking-overview-codes-and.html

[2] https://cdn.standards.iteh.ai/samples/63434/f460de8a1261420a92f1195a8e329213/ISO-11469-2016.pdf