Why Designers Continue To Replace Metal Parts With Engineering Plastics

Mechanical engineers and designers are increasingly replacing existing metals parts with components made from engineering plastics. A common misconception is that this trend is based purely on reducing the initial cost per part, but the reality is quite different. Engineering plastics are often more expensive than metals, but provide benefits such as improved performance, longer part life, and reduced downtime. This long-term, “overall cost of ownership” approach is driving a strong market for engineered plastic solutions.


Here are a few of the product features and benefits that are driving the trend towards increased use of engineering plastics.

Wear Resistance
In high-wear applications, many plastic materials will outperform brass & other metal bearing materials. Plastics such as Nylon, UHMW, PTFE, Acetal and Turcite® offer natural lubricity to increase wear resistance and extend the part life of bearings, rollers, gears, and seals.

Lightweight
When replacing metal parts, plastics will typically reduce the part weight by 30% to 50%.This can translate to significant energy savings when used in applications such as transportation, linear motion, and material handling.

Temperature Resistance
Plastics, ceramics, and composites have been developed which resist both extremely high & extremely low cryogenic temperature ranges with minimal loss of mechanical properties. Materials such as Celazole® PBI can continually operate at up to 750°F, while materials such as Kel-F® PCTFE can operate at -400°F.

Impact Resistance & Shock Absorption
Many plastics and composites offer excellent impact resistance. Materials such as Polycarbonate are used for impact-resistant glazing and shields. Nylon and Polyurethane will absorb impact shock and isolate stress points to protect surrounding components.

Insulation Properties
Many plastics have excellent insulation properties, reducing heat, and improving product reliability. Laminates such as G-10/FR-4, GPO-3 and LE Phenolic are used extensively in electrical and transportation industries to insulate from heat and electrical shock. Thermoplastics such as PTFE and Meldin® work well in high-temperature insulating applications.

Corrosion Resistance
Metals are inherently susceptible to corrosion from moisture, acids, and organic solvents. Many plastics were designed specifically to combat these problems. Materials such as PVC, CPVC, Polypropylene, and PTFE offer superior corrosion resistance at an economical price.

Medical Approval
Many plastics have been approved for use in medical applications ranging from heart pump valves to endoscopic instruments. Products meet FDA, USP Class VI, and ISO 10993 standards. Such materials include Radel®, PEEK, Ultem®, and Polycarbonate.

Fire Safe
Dozens of plastic materials have been developed to meet common aircraft, transportation, semiconductor, and UL ratings for flame and smoke safety. Specifications include FAR, FTA, FRA, ASTM, UL and FM. In the semiconductor industry materials meeting the FM-4910 specification have reduced or eliminated the need for costly fire-suppression systems, and thus have reduced overall equipment costs. In some cases, the use of these materials have even reduced insurance costs in high-liability applications. Common flame-retardant and flame-safe materials include: Kydex®, Boltaron®, Halar®, CP7-D, FRPP, Corzan® CPVC, and Kynar® 740 PVDF.

High Purity
Plastics have long been a crucial product used in the manufacturing of high-purity fluid & gas handling applications. Many plastics have eliminated the concerns of out-gassing, leaching, and other contamination in crucial high-purity systems. These products include: PTFE, PFA, FEP, Halar® and Kynar® PVDF.

Static Control
Several plastics and composites have anti-static qualities to prevent the build up of an electric charge. Products range from conductive materials 10^2-10^6, and static dissipative 10^6-10^10, to highly resistive materials 10^10-10^12.


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KYDEX® Sheet Available from Professional Plastics Website

KYDEX® sheet is manufactured by Kleerdex Company, a supply partner of Professional Plastics. KYDEX® sheet is an extremely durable thermoplastic alloys extruded in a range of colors, patterns, textures, thicknesses and grades. Specialized grades of KYDEX® sheet meet specific UL, FAR, MVSS, ASTM and/or BS fire ratings , and exhibit exceptional mechanical properties and chemical resistance required to produce components intended for demanding applications.

Grades of  KYDEX® sheet:

•KYDEX 100 Ultra high impact, high performance, fire-rated sheet suitable for a broad range of demanding applications.

•KYDEX 101 White #62000 or black #52114 substrate with colored, weatherable cap for thermoforming letter backs of electrical signage. Eliminates painting.

•KYDEX 107 For National Sanitation Foundation applications. Numerous textures/sizes, limited colors. FDA approved raw materials. Cost competitive with ABS sheet.

•KYDEX 110 Super tough, durable METALLIC-colored, a proprietary alloy sheet, sets new standards for thermoformers in: formability, rigidity, breakage resistance, fire retardancy and aesthetics.

•KYDEX 115 Rigid, sag-resistant ceiling panel grade in .080" (2.03mm) thickness, available pre-cut. Class 10 rated for clean rooms. Also for food plants, computer rooms, operating rooms, etc.

•KYDEX 130 High performance sheet with integral granite pattern in five colors. Rated Class I/A for non-wallcovering applications. UL 94 V-0 and 5V fire rating.

•KYDEX 150 High performance sheet for building product applications. Rated Class I/A in gauges to .060" (1.52mm); Class II/B in gauges to 0.093" (2.36mm). UL listed.

•KYDEX 152 AR Super tough, durable sheet sets new standards for thermoformers and membrane pressers in formability, rigidity, breakage resistance, and abrasion resistance.

•KYDEX 152 WG Super tough, durable sheet is available in five aesthetically pleasing woodgrain patterns. This material brings new dimensions to thermoformers and membrane pressers in extensibility, toughness, and fire retardancy in a woodgrain design.

•KYDEX 160 High performance sheet for building product and clean room applications. Rated Class I/A and Class 10 in gauges to .125" (3.12mm). UL listed.

•KYDEX 160A A thermoplastic sheet that is used for laminating and thermoforming applications. Meets the Australian fire retardant properties of AS 1530.3 and 1530.4.

•KYDEX 161 A proprietary, high performance thermoplastic sheet that meets the M1 requirement for the French Epiradiateur Test NFP 92-501.

•KYDEX 1900 Mid-temperature aircraft grade with improved heat distortion characteristics for higher in-service temperatures 168-178°F (75-81°C). Meets FAR requirement 25.853(a).

•KYDEX 200 General purpose sheet with good impact resistance, excellent extensibility and solvent resistance. Cost competitive with many other thermoplastics.

•KYDEX 301 A proprietary Bi-layer thermoplastic sheet that is cost competitive with fire retardant ABS (FR-ABS) formulations but with superior properties ... it is less hygroscopic than FR-ABS ... eliminates drying.

•KYDEX 510 KYDEX sheet of any color with a clear, weatherable cap. Caps also available with black/white or rust/gray granite patterns.

•KYDEX 550 Weatherable, monolithic (no cap) sheet in limited light colors. Excellent impact resistance.

•KYDEX 6185 High-temperature aircraft grade with improved heat distortion characteristics for higher in-service temperatures 180-195°F (82-90.5°C). Meets FAR requirement 25.853(a).

•KYDEX 6200 High performance grade for mass transit vehicle interiors. Meets FTA and FRA fire requirements. Meets low smoke generation requirements.

•KYDEX 6565 High performance grade for aircraft interiors. Meets FAR fire requirements 25.853 (a) and (d).Meets low smoke and low RHR generation requirements.

•KYDEX L Damage-resistant laminating material. Ratings of Class I/A and UL 94 V-0 in gauges to .040 (1.02mm). Can also be thermoformed and membrane pressed.

•KYDEX T High impact, high performance, fire-rated sheet. Cost competitive with flame retardant ABS, but with great impact and extensibility.

•KYDEX V Recycled grade of Kydex "utility black" #52065 sheet. Excellent performance-to-cost ratio.

•KYDEX V100 Recycled black #52114 sheet. Rated UL 94 V-0. Excellent performance-to-cost ratio.

•KYDEX V102 Recycled beige #72401, gray #52346, or black #52114 Kydex sheet with cap in select colors. Rated UL 94 V-0 and 5V.

•KYDEX V103 A recycled grade of a proprietary thermoplastic sheet that is cost competitive with other grades of thermoplastic sheet while offering improved performance.

For more information visit Professional Plastics Kydex Web Page

Or call (888) 995-7767 for the nearest Professional Plastics location.