5 Common Mistakes to Avoid When Selecting Polymers for Electric & Electronics Applications

Hello and welcome to a new post. In today’s post, we discuss five common mistakes to avoid when selecting polymers for electric and electronics applications such as connector housings.

Proper polymer material selection is the most effective antidote for battling plastic part failure and my aim is to help the plastics community to increase their confidence in material selection, especially with high performance polymers and recycling plastics. 

Avoid these 5 common mistakes when selecting polymers for electric and electronics applications

1️⃣ Ignoring Electrical Properties

-Failing to check dielectric strength, insulation resistance, and tracking resistance (CTI) can lead to electrical failures or safety hazards.

2️⃣ Overlooking Flame Retardancy Requirements

-Not verifying compliance with standards like UL 94 V-0 can result in non-compliant products and increased fire risk.

3️⃣ Neglecting Chemical and Environmental Resistance

-Forgetting to assess resistance to chemicals, moisture, and environmental stress can cause premature degradation, corrosion, or loss of performance.

4️⃣ Disregarding Dimensional Stability and Creep

-Choosing materials that warp, shrink, or deform under heat or load may compromise connector fit, function, and reliability over time.

5️⃣Underestimating Processability and Manufacturability

-Selecting polymers that are difficult to mold, have poor flow, or are incompatible with existing tooling can lead to defects, higher scrap rates, and increased production costs.

Figure 1: 5 common mistakes to avoid when selecting plastics for electrical applications.

Thanks for reading & #findoutaboutplastics

Greetings,

Herwig Juster

🎥Join my YouTube channel community 

🔎I review your polymer material selection and plastic part design - contact me here

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📊 Discover your Polymer Material Selection score by taking quick test here

Literature: 

[1] https://www.findoutaboutplastics.com/2025/04/nature-is-built-on-5-polymers-modern.html

High Performance Thermoplastic Selection - Polyether (PPE, PAEK, PEEK, PEKK) [Part 2C - cont.]

Hello and welcome to the Part 2C of our High Performance Thermoplastics selection blog series. Today we discuss the Ether-Ketone Polymer family (PAEK and PEEK), their chemistry and production processes, their main properties, processing methods, and applications.

Overview - 6 major high performance thermoplastics families (“the magnificent six”) 

In this blog post series we 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)

3. Key properties and design data for selection

4. Polymer Material Selection 4-stage funnel methodology (POMS-Funnel-Method)

5. Examples for Ultra- and high performance polymer selection

1. Introduction to Polyaryletherketones

Screening the patent literate regarding the invention of Polyaryletherketones, it was reported independently by Imperial Chemical Industries (ICI) and DuPont. Polyetheretherketone (PEEK) was first produced in 1978 by scientists at ICI in the UK, with the first batch made on November 19, 1978, by John B. Rose and Philip A. Staniland's team. ICI commercialized it as Victrex PEEK in the early 1980s, initially for demanding defense and aerospace uses, becoming a high-performance thermoplastic known for its strength, temperature resistance, and chemical inertness. 

In general, the aromatic ether ketone polymer family, including Polyetheretherketone (PEEK), Polyaryletherketone (PAEK), and Polyetherketoneketone (PEKK) are high-performance thermoplastics valued for their outstanding mechanical, thermal, and chemical properties. Recent research and industry trends are increasingly focusing on PAEK blends to further tailor and enhance performance for demanding applications.

2. Chemistry and Production

• Chemical Structure:
  All three are aromatic polyketones with ether and ketone groups.
  • PEEK: Regular ether/ketone sequence.
  • PAEK: Family with variable ether/ketone ratios, allowing for property tuning.
  • PEKK: Higher ketone content, affecting crystallinity and processing.

• PEEK Polycondensation Process:

  • Mechanism: PEEK is produced via a high-temperature polycondensation reaction, typically through nucleophilic aromatic substitution.
  • Monomers: The main industrial method (patented by Victrex PLC in the late 1970s) uses 4,4'-difluorobenzophenone (or 4,4'-dichlorobenzophenone) and hydroquinone (1,4-benzenediol or bisphenol).
  • Solvent & Catalysts: The reaction occurs in a high-boiling polar aprotic solvent, diphenyl sulfone (DPS), with a mixture of potassium and sodium carbonate as the base.
  • Process Steps:
    • Salt Formation: Hydroquinone reacts with alkali metal carbonates to form a bisphenate salt, releasing water and CO₂.
    • Polycondensation: The bisphenate salt reacts with 4,4'-difluorobenzophenone, displacing fluorine atoms and forming ether linkages, with potassium and sodium fluoride as byproducts.
    • Purification: The resulting high-molecular-weight PEEK powder is cooled, crushed, and washed with hot water and organic solvents (e.g., acetone) to remove residual salts and solvent.
    • Drying: The purified polymer is dried, often under vacuum at ~120°C.

• PAEK Blends:

  • Produced by blending PAEK with other polymers or additives to achieve specific property profiles, such as improved toughness, flexibility, or processability.

3. Properties

The ether/ketone ratio impacts the thermal transitions of ether-ketone polymers. Table 1 illustrates the influence of the ether/ketone ratio on the thermal transitions of various Polyaryletherketones. As the ether/ketone ratio increases from 1.0 to 3.0, both the glass transition temperature (Tg) and the melting temperature (Tm) of the polymers decrease. Specifically, PEK (ether/ketone ratio 1.0) exhibits the highest Tg and Tm, while PEEEK (ratio 3.0) shows the lowest values. This trend demonstrates that increasing the ether content in the polymer backbone reduces the thermal transitions of Polyaryletherketones by enhancing chain flexibility and increasing the free volume between polymer chains.

For anyone working with high-performance materials, understanding these trends is key to selecting the optimal polymer for demanding applications. 

Table 1: Aromatic Ether-Ketone Polymers - influence of the ether/ketone ration on thermal transitions.

• PEEK has high thermal stability (max. continuous use temperature UL746B = 260°C; max short-term use temperature: 310°CHDT 1.8 MPa = 160°C), mechanical strength (tensile modulus = 4000 MPa; tensile strength = 110 MPa), inherent flame retardant (UL94 V0), and high chemical resistance.

• Blends:
  • Blending ketone-polymers with other polymers (e.g., polyetherimide, polyphenylene sulfide, liquid crystal polymers, or elastomers) can improve processability, impact strength, and tailor crystallinity.
  • Nanofiller or fiber-reinforced PAEK blends offer enhanced mechanical, thermal, and tribological properties.
• PEKK has a slower crystallization rate which makes it good for 3D printing.

4. Processing Methods

• Injection Molding, Extrusion, Compression Molding, Machining, 3D Printing.
• PAEK Blends:
  • Improved processability and lower processing temperatures compared to pure PAEK.
  • Blends can be tailored for compatibility with specific manufacturing techniques.
• Recycling of PEEK: Regrind of spure, gates and faulty parts can be used without problem up to a level of 25%. Important is to blend the regrind with virgin PEEK pellets to ensure uniform processing and use consistent amount of regrind. 

5. Applications

• Aerospace: PEEK was originally developed for the aerospace industry. Its high strength-to-weight ratio, flame retardancy (meeting FST standards), and resistance to aerospace fluids like jet fuel are highly valued for improving fuel efficiency and safety: 
• Structural components: Lightweight brackets, clamps, and clips can replace heavier aluminum parts without compromising strength.
• Engine components: Seals, bearings, and insulation in turbine systems that withstand high temperatures and pressures.
• Interior components: Used in seat frames and cabin panels due to its flame-retardant properties and durability.
• Electrical insulation: Cable insulation and various electrical connectors due to its high dielectric strength. 
• Automotive: 
• Engine & Transmission: Thrust washers, seal rings, bushings, and gears in transmission and engine systems, where they endure high temperatures and mechanical stress.
• Braking Systems: Components in ABS/ESC brake systems and brake wear sensors.
• Fuel Systems: Seals, O-rings, and valve seats in fuel injection systems and pumps, due to resistance to various fuels and oils.
• Traction motors: magnet wire coating by using direct extrusion on copper wire. 
• Electronics
• Medical: Surgical equipment and long-term implantable devices, because of its biocompatibility, radiolucency (transparent to X-rays), and ability to withstand repeated sterilization. Applications include handles for reusable surgical instruments, sterilization trays, and components in fluid transfer systems and pumps (e.g., in dialysis equipment). 
• Oil & Gas: In the demanding high-pressure, high-temperature (HPHT) and corrosive environments of the oil and gas industry, PEEK's resistance to hydrocarbons, steam, and aggressive chemicals is crucial. Applications include sealing systems, downhole tools, Valve and Pump Components.
• 3D Printing.

• PAEK Blends:
  • Used where a balance of toughness, chemical resistance, and processability is required.
  • Fiber- or nanoparticle-reinforced blends are ideal for lightweight, high-strength parts in aerospace and automotive sectors.

6. Economic Aspects

• Cost:
  High compared to engineering and other high-performance polymers, however blends can sometimes reduce costs by enabling easier processing or using less expensive co-polymers.
• Value:
  Blends offer tailored solutions, potentially reducing total cost of ownership through improved performance and manufacturability.

7. Suppliers

• PEEK: Victrex (VICTREX 450G™), Syensqo (KetaSpire®), Evonik (VESTAKEEP®),  Zhejiang Pfluon Chemical (PFLUON®), Zhongyan Polymer Materials Co (ZYPEEK).
• PAEK: Victrex (LMPAEK™), Syensqo (AvaSpire® PAEK).
• PEKK: Arkema (Kepstan®), Syensqo (APC and Cypek).
• Ether/Ketone Blends: Offered by major suppliers and custom compounders; specific formulations may be proprietary.

Key Takeaway:

Ether ketone polymers represent a versatile and growing area in high-performance polymers, enabling engineers to fine-tune properties for specific application needs—especially where a balance of toughness, processability, and chemical resistance is critical.

In the next part, we will discuss Liquid Crystal Polymers (LCP) and High-performance Polyesters (Polycyclohexylene terephthalate - PCT).

Thanks for reading & #findoutaboutplastics

Greetings,

Herwig Juster

🎥Join my YouTube channel community 

🔎I review your polymer material selection and plastic part design - contact me here

🔥 There is a problem keeping you awake - My personal website for Polymer Consulting

📊 Discover your Polymer Material Selection score by taking quick test here

Literature: 

[1] https://pmc.ncbi.nlm.nih.gov/articles/PMC10575340/#polymers-15-03943-f004

[2] https://www.vink-kunststoffe.de/produkte/peek/technisches-datenblatt-peek.pdf

[3] https://link.springer.com/chapter/10.1007/978-94-011-7073-4_18

[4] https://www.syensqo.com/en/brands/ketaspire-peek

[5] https://www.victrex.com/en/products/polymers/peek-polymers

[6] https://www.findoutaboutplastics.com/2020/11/plastic-part-failure-part-2-antidote.html

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