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Author Archives: Mike Fredrich

  1. Thermoset Plastics vs. Metal

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    In the manufacturing sector, two of the most commonly used types of materials are metals and plastics. These material groups can be further divided into numerous subcategories, each of which offers distinct characteristics that make it suitable for particular applications. For example, metal can be classified into ferrous and non-ferrous materials, while plastic can be classified into thermoset and thermoplastic materials.

    Thermoplastics are plastic materials that can be ground and mixed with virgin resin to be reused repeatedly, while thermosets cannot be reworked once they’ve been cured. The latter is commonly used as an alternative to various metals in manufacturing projects due to their lower production costs, lighter weight, better vibration resistance, and greater corrosion resistance.

    Below, we provide a more in-depth discussion of metal, including what properties it exhibits and how it compares to thermoset plastics.

    What Is Metal?

    Metals are a broad classification of materials. Examples include aluminum, copper, brass, bronze, stainless steel, steel, and titanium. They vary regarding physical, mechanical, chemical, thermal, and electrical properties depending on their composition. However, in general, they offer good thermal and electrical conductivity, malleability, and ductility.

    Compared to thermoplastics, metals offer a variety of advantages, such as:

    • Higher heat resistance. Metals have a high melting point, which makes them less likely to experience damage or degradation when exposed to high temperatures.
    • Greater strength. Metals generally have greater strength than plastics.
    • Broader versatility. Metal can be used in various manufacturing processes, enabling manufacturers to produce a range of metal parts and products.
    • Better cost-effectiveness. Metals generally serve as a cost-efficient option for high-volume or long-term production operations.

    However, they also come with a few disadvantages that have led manufacturers to turn to thermoset plastics as an alternative material choice.

    Advantages of Thermoset Plastics Over Metal

    While metal is used to create a wide range of components, products, and structures, it is not suitable for every manufacturing project. Some of the issues manufacturers have with metals include:

    • May require post-fabrication processes. Many fabricated metal components need to undergo finishing operations (e.g., painting, polishing, and deburring) which can increase production time and costs.
    • May have design limitations. Certain metals have a viscosity and molten flow behavior that are not conducive to creating complex shapes.
    • May have higher tooling costs. The cost of tooling for metal fabrication operations is often more expensive than comparable tooling for plastic fabrication operations.

    Thermoset plastics overcome these limitations, making them a commonly used alternative material. Some of the other advantages thermosets have over metals include:

    • Lower cost. In addition to lower tooling costs, thermoset plastics often come with a lower price point than metals, especially aluminum and steel. Additionally, since they can be formulated into a variety of colors, they generally do not have to undergo painting or coating operations to meet aesthetic requirements.
    • Lighter material weight. Plastics can offer comparable strength at a fraction of the weight of metals. This quality makes them ideal for use in applications where low weight is critical.
    • Better vibration resistance. Plastics reduce vibrations, resulting in parts that generate less noise and produce less damage.
    • Greater corrosion resistance. Certain metals are susceptible to corrosion and oxidation. Most plastics, including thermosets, demonstrate an inherent resistance to both.
    • Easier compliance with industry regulations. Thermoset plastics are available in numerous formulations. This broad selection makes it easy for manufacturers to choose a material that meets product specifications and industry standards (e.g., FDA or RoHS).

    Working With MCM Composites’ Thermoset Plastics

    Need a manufacturing partner with experience working with thermoset plastics? The experts at MCM Composites have got you covered! We specialize in thermoset plastic molding. Whether you need help completing a metal-to-plastic conversion, developing components for high-temperature applications (up to 500° F), or turning multi-piece assemblies into a single molded piece, our team will help you manufacture your thermoset plastic parts.

    To learn more about our thermoset manufacturing capabilities and how they can benefit your project, contact us today. To discuss your thermoset molding needs with one of our team members, request a quote.

  2. Thermoset Plastics vs. PEEK

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    There are two main categories of plastics: thermosets and thermoplastics. Due to a change in molecular structure, thermoset materials keep their form and remain solid under heat once cured. Thermoplastics can be repeatedly reground, reheated and remolded. In addition to the difference in their reactions to the application of heat, these material groups also demonstrate other distinct characteristics that make them suitable for different use cases.
    Below, we highlight PEEK, a commonly used engineered thermoplastic material. We outline what properties it exhibits, what it is used for, and how it compares to thermoset plastics.

    What Is PEEK?

    Polyetheretherketone (PEEK) is a semi-crystalline thermoplastic with excellent mechanical and chemical properties. In addition to resistance to chemicals, radiation, water absorption, and wear, it offers thermal stability in temperatures up to 480° F. It can also face hot water or steam without compromising its physical properties. These qualities, combined with its strength and stiffness, make it a suitable material for parts and products used in demanding environments. It is commonly used to make components for industries such as aerospace, automotive, medical, and semiconductor.

    Advantages of Thermoset Plastics Over PEEK

    As a high-performance thermoplastic material, PEEK finds use in many industrial applications. However, thermoset plastics demonstrate a variety of characteristics that can make them a better option for certain manufacturing projects. For example, since thermoset plastics undergo an irreversible chemical change when cured, they typically offer better thermal stability than any thermoplastic material, including PEEK.
    Other key advantages thermosets have over PEEK include:

    • Greater design freedom. Thermosets can be molded into nearly any geometry, which provides designers and engineers with greater freedom when creating a design.
    • Better physical and chemical properties. In addition to thermal stability, thermosets offer superior strength, stiffness, dimensional stability, and durability when compared to thermoplastics. As a result, components made from them can withstand harsher operating and environmental conditions. They also exhibit other advantageous physical properties, such as low water absorption, low smoke and toxicity, and low specific gravity.
    • Lower cost. In addition to being generally less expensive than alternative materials, thermoset plastics can also save money during the manufacturing process. A single mold can be used to create complex parts with many options in using inserts in a product design. Inserts can be molded-in during the molding cycle or tapped/press-fit into the part after molding.

    Working With MCM Composites’ Thermoset Plastics

    Need a manufacturing partner with experience working with thermoset plastics? Turn to the experts at MCM Composites. We can help you develop the right molding solution for your PEEK application, whether it involves environmental temperature requirements up to and exceeding 500°F or multi-piece to single-piece conversions.
    For more information about our thermoset molding capabilities and how they can benefit your manufacturing processes, contact us today. To discuss your thermoset molding needs with one of our team members, request a quote.

  3. Thermoset Plastics vs. Ultem Plastics

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    Thermoset plastics are a popular type of molding compound used in many engineered plastic applications. Once thermoset plastics are heated and start to set, the curing process chemically alters the material so it can’t be reground or reused. Thermoset materials are cost-effective and durable, making them an ideal choice for many manufacturing projects. Conversely, thermoplastics can be returned to a ground state and recast or reused multiple times without altering the chemical structure of the material. This blog will discuss the differences between thermoset plastics and Ultem®, a specific type of thermoplastic.

    What is Ultem?

    Of all the different thermoplastic materials used for manufacturing goods, Ultem is one of the most advantageous for high-heat applications. This polyetherimide compound features a high melting point for a thermoplastic, which means it can be used to produce parts that stay rigid and reliable at temperatures up to 340°F. The high melting has led some engineers to choose Ultem in situations where a thermoset plastic might traditionally be used. Ultem also features good dielectric properties, high strength, rigidity, and resistance to most chemical damage.

    Some of the most common applications for Ultem include:

    • Circuit boards
    • Electrical insulators
    • Electronic insulators
    • Eyeglasses
    • Food prep equipment
    • Jet engine components
    • Manifolds
    • Medical components
    • Microwaves
    • Sterilization equipment

    Thermoset Plastic Advantages Over Ultem

    Despite the benefits offered by Ultem and other thermoplastics, thermoset plastics remain advantageous in many applications. Manufacturing with thermoset materials presents many key advantages that are valuable during manufacturing and during the lifecycle of the product. The advantages of thermosets over Ultem include:

    Cost-Effectiveness

    Thermoset compounds are less expensive than thermoplastics, which reduces overall production costs. Lower material costs also allow for a greater margin of experimentation and modification without exceeding a set budget.

    Manufacturability

    Thermoset compounds can be molded into products with any geometry. No matter how complex the product design is, manufacturers can use thermosets to create solid, tough pieces with a high degree of structural integrity. This is ideal for parts that face extreme end-use environments and need to meet tight tolerances for complex configurations.

    Physical Properties

    Thermoset materials offer a wide variety of beneficial characteristics. After the curing process, thermoset parts have a high degree of rigidity and can withstand impact damage. The products are also strong and resistant to heat damage. Because of the excellent manufacturability thermoset plastics offer, they can be molded to extremely tight tolerances. This is ideal for electronic product components or complex mechanical assemblies with little room for error or misalignment.

    Quality

    Thermoset plastics feature an excellent strength-to-weight ratio. That means the products offer a high degree of strength while still being light and easy to handle. They dampen sound, resist creep, and have a low coefficient of friction that mitigates damage from abrasion. Thermosets are ideal for parts that need to retain quality and structural integrity long-term.

    Stability

    Thermoset products are stable and resistant to impact damage, UV radiation, fluid exposure, and heat. Some thermosets can retain their stability in environments that reach sustained temperatures of 500°F.

    Thermoset Plastics and MCM Composites

    At MCM Composites, we offer an extensive array of manufacturing services designed to create high-quality thermoset products. We offer thermoset injection molding and thermoset compression molding services for customers across industries. Contact us today or request a quote to see how our thermoset plastic molding capabilities can support your design.

     

     

     

  4. Thermoset Plastics vs. Thermoplastics

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    While you may have heard the terms thermoset plastic and thermoplastics used synonymously, they are two different products. Composed of polymer powders, they each react differently when exposed to heat. While thermoset plastics are cured by heat, they can only be formed once and are not suitable for exposure to extremely variable or high temperatures. Engineered thermoplastics, however, remain pliable and can be ground and reformed without changing the chemical composition.

    The Basics

    Thermosets are a popular alternative to metal. Often they are comparable in strength and rigidity, but have greater corrosion resistance with less weight than metal. Thermoset plastics are not only heat-resistant, creep resistant, and ideal for tight tolerances, but they also have higher impact resistance and durability than thermoplastics. They can be less expensive to source and form than either metal or engineered thermoplastics, and the fact that they do not require finishing makes them even more cost and time-efficient. 

    MCM works with most types of thermoset plastics, such as:

    • Carbon fiber epoxy resin 
    • Phenolics 
    • BMC (bulk molded compounds) 
    • Fluoropolymers, 
    • Melamine  
    • Urea-formaldehyde

    Thermoplastics include Polyethylene, Acrylonitrile Butadiene Styrene (ABS), Polymide (Nylon), Polycarbonate, Polypropylene, and High Impact Polystyrene (HIPS).

    Their Differences

    While thermoplastics are more suited to some applications like plastic bags, plastic films,  clothing, carpeting, and flexible packaging, there are some distinct advantages to choosing thermosets over thermoplastics.

    Cost

    Thermosets can be less expensive to procure and fabricate than either metals or thermoplastics and do not require finishing. Using a single mold, they can be formed into complex geometries or multi-part components, providing economies in production time and cost. Injection molding of thermosets requires less heat and pressure than thermoplastics, making them more cost-efficient to produce.

    Quality/Stability

    Unlike thermoplastics, thermoset plastics are heat stable, retaining their shape and chemical composition when reheated. Thermosets also have an exceptional strength-to-weight ratio, temperature resistance, corrosion resistance, and UV stability. 

    Physical Properties

    Resistance to high heat, petrochemicals, fire, and corrosion make thermosets extremely versatile. They exhibit low creep and exceptional dimension retention, strength, rigidity, and low fluid absorption, as well as antimicrobial qualities. Thermosets also possess excellent electrical and sound insulating qualities. 

    Surface Finish

    The efficient process used for forming thermosets produces high-gloss surfaces without additional finishing or coating. The resulting finish is also much harder than that of thermoplastics. 

    Manufacturability

    Thermosets can be formed into any geometry using a variety of molding processes such as injection molding, and compression molding. Highly complex shapes and multi-part components are easily created from thermoset plastics. 

    Their Applications

    Both thermoset plastics and thermoplastics can be easily formed, making them attractive alternatives to metals in a variety of sectors and industries. The aerospace and automotive industries, as well as the energy sector, including oil, gas, and solar, have seen huge benefits by leveraging the exceptional versatility of thermosets and thermoplastics. Electrical components, durable manufactured goods, and heavy-duty construction equipment manufacturers routinely use thermosets and thermoplastics. While thermoplastics are highly flexible and recyclable, thermosets will be preferred in applications requiring strength at temperatures up to 500° F.

    Applications that make extensive use of thermoset plastics include but aren’t limited to:

    • Aerospace components
    • Appliance parts
    • Arc shielding
    • Connector housings
    • Electrical and electromechanical components
    • Food grade parts & food and beverage processing equipment
    • Marine applications
    • Medical devices and equipment
    • Outdoor furniture
    • Outdoor lighting
    • Parts that require insert molding
    • Public transportation seating

    Thermoset Plastics From MCM Composites

    MCM Composites, LLC is an industry leader in thermoset plastic molding, including injection molding and compression molding. We also offer secondary services for injection molded parts such as tapping, drilling, coating, and multi-piece assembly. Our experienced team works with both customers and suppliers to determine the ideal material for the specific application.

    MCM Composites produces over 1,000 different parts for customers throughout the United States, Canada, China, Mexico, and the Caribbean in our ISO 9001:2015 certified mold shop. We are committed to providing the highest quality thermoset plastic components in strict conformance with our customers’ specifications. For more information about our capabilities, contact us today or request a quote. 

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