Material Selection for Plastic Components: A Consultant’s Perspective

Mechanical and Thermal Properties

Every application places specific demands on the strength, flexibility, and temperature resistance of a plastic. We analyse polymer mechanical properties, such as tensile strength, impact resistance, and flexural modulus, to shortlist viable candidates.

For high-temperature environments, temperature-resistant plastics like PEEK, PPS, or PTFE may be necessary. Applications in cold environments may prioritise flexibility and low-temperature toughness.

Chemical Resistance and Compatibility

Understanding the chemical environment a plastic component will be exposed to is essential. Certain polymers resist acids, oils, solvents, and UV light better than others. This is especially vital in sectors such as pharmaceuticals, agriculture, and automotive.

Chemical resistance of plastics is tested through industry-standard methods. For instance, FDA-approved plastic materials are often required for food contact and medical applications.

Processability and Manufacturing Requirements

Some plastics are easier to mould, extrude, or 3D print than others. Selecting a material that aligns with your chosen production method ensures design intent is maintained. Our team supports material selection for injection moulding and extrusion processes by advising on melt flow, shrinkage, and tooling compatibility.

Regulatory and Safety Considerations

Medical and food-grade products must meet strict safety regulations. We help clients navigate global standards by identifying biocompatible plastics, flame retardant polymers, and UV-stable plastics suited for outdoor or high-exposure environments.

Engineering Plastics vs Commodity Plastics

Engineering plastics offer improved thermal and mechanical properties over commodity plastics like polyethylene or PVC. For load-bearing, high-temperature, or chemically harsh environments, engineering polymers such as nylon, PBT, or polycarbonate provide better performance longevity.

Selecting between thermoplastics vs thermosets depends on the component’s shape complexity, performance demands, and recyclability requirements. Thermoplastics can be reheated and reshaped, making them easier to process and recycle. Thermosets, however, provide enhanced dimensional stability and thermal resistance once cured.

Sustainability in Material Selection

Sustainable plastic materials are becoming a priority across multiple industries. Biodegradable resins, recyclable thermoplastics, and bio-based polymers are now viable for many applications without sacrificing performance.

As biopolymer consulting specialists, we work with manufacturers to integrate sustainable materials into their supply chain. Whether it’s for compliance reasons or ESG-driven decision-making, the demand for greener plastics is growing rapidly.

Matching Performance with Cost

A critical factor in plastic material selection is balancing material cost vs performance. High-performance polymers are costly but offer unmatched durability in harsh conditions. We analyse your use-case, operating environment, and required lifespan to avoid overengineering or unnecessary expenditure.

Through our plastic failure analysis service, we can retrospectively identify if material choice was the root cause of component breakdowns. This helps prevent future product recalls, warranty claims, and customer dissatisfaction.