Materials database

Acrylonitrile Butadiene Styrene — the most widely used amorphous engineering/commodity thermoplastic. Excellent balance of toughness, rigidity, and processability. Good surface finish and paintability. Not UV-stable without additives. Trade names include Novodur (INEOS Styrolution), Terluran (INEOS), Cycolac (SABIC). Used for automotive interior trim, appliance housings (vacuum cleaners, monitors), LEGO bricks, 3D printing filament, and pipe fittings.

Expanded Polystyrene — a closed-cell rigid foam made by expansion of pre-foamed PS beads with pentane blowing agent. Density typically 10-50 kg/m³ (98% air by volume). Outstanding thermal insulation (lambda 0.033-0.040 W/m·K), excellent shock absorption, water-resistant, lightweight. Primary uses: building insulation (walls, roofs, floors), packaging (cushioning, cold chain), molded parts (helmets, coolers). Trade names include Styropor (BASF original, 1950), Neopor (graphite-enhanced), Airpop (industry collective brand).

General Purpose Polystyrene (GPPS), also called Crystal PS — an amorphous, glassy, transparent thermoplastic with sparkle appearance. Excellent optical clarity (~88-92% light transmission), high stiffness, good dimensional stability, low cost. Inherently brittle (elongation 1-3%) and notch-sensitive — HIPS is the impact-modified alternative. Commercialized in the 1930s; today mainly produced by INEOS Styrolution, Trinseo, and TotalEnergies. Typical applications: disposable cups, CD cases, Petri dishes, yogurt containers, cosmetic packaging, costume jewelry, toys, office equipment.

High Impact Polystyrene — polystyrene toughened with 5-15% polybutadiene rubber dispersed as rubber particles in the PS matrix. Opaque milky-white (rubber scatters light). Impact strength 4-10× higher than GPPS, with corresponding reduction in transparency and stiffness. FDA-compliant natural grades approved for food contact. Excellent machinability and dimensional stability — frequent choice for pre-production prototypes and housings. Typical applications: TV housings, air conditioner exteriors, copier/printer housings, toys, frozen food trays, refrigerator interior liners, yogurt cups.

High Density Polyethylene — the highest-volume plastic globally (>30M tons/year). Linear chains with minimal branching give higher density and strength vs LDPE. Excellent chemical resistance, FDA/food-safe, very low moisture absorption, and good impact resistance down to -30°C. Used for pipes, bottles, containers, fuel tanks, cutting boards, playground equipment, and geomembranes.

Low-density polyethylene — branched chain structure gives flexibility, transparency, and easy processing. THE film/packaging polymer: cling wrap, carrier bags, squeeze bottles, shrink wrap. Also used for cable insulation, agricultural film, and coatings. Lower density (0.91-0.93) and strength than PE-HD but much more flexible.

Linear low-density polyethylene — short-chain branching via copolymerization with alpha-olefins (butene, hexene, octene). Better puncture resistance, tear strength, and seal strength than PE-LD at same density. THE modern stretch wrap and food packaging film. Also used for agricultural film, liners, bags, and blown film. Largely replacing PE-LD in film applications.

Ultra-High Molecular Weight Polyethylene — the highest impact-strength thermoplastic. Molecular weight 2-6 million g/mol. Self-lubricating, extremely wear-resistant (15x better than carbon steel), and chemically inert. Used for hip/knee implant bearings, conveyor guides, dock fenders, chute liners, food processing equipment, and ballistic armor (Dyneema/Spectra fiber form).

Glycol-modified Polyethylene Terephthalate — an amorphous copolyester produced by adding cyclohexanedimethanol (CHDM) as a co-monomer, suppressing crystallization. Unlike semi-crystalline PET, PET-G is fully transparent and easy to thermoform without embrittlement. Excellent chemical resistance, FDA-compliant for food contact, easy to fabricate by vacuum forming, extrusion, and injection molding. Broadly used in 3D printing as a PLA alternative with better toughness and heat resistance. Typical applications: printed retail displays, credit card overlay films, medical blister packs, cosmetic bottles, machine guards, 3D printing filament, thermoformed trays.

Polymethylmethacrylate — the optical-quality plastic. 92% light transmission (better than glass). Excellent weathering resistance and UV stability. Hard but brittle (no yielding — fractures). Trade names include Plexiglas (Röhm/Evonik), Perspex (Lucite), Acrylite (Mitsubishi). Used for signs, displays, light guides, automotive tail lamps, aquariums, skylights, and protective shields.

Polypropylene is the most produced plastic globally by volume. Semi-crystalline thermoplastic with excellent chemical resistance, low density (0.90–0.91 g/cm³ — lightest engineering plastic, floats in water), good fatigue resistance (living hinges) and low cost. Available as homopolymer (higher stiffness) and copolymer (better impact). Trade names: Moplen (LyondellBasell), Sabic PP (SABIC), Borealis PP. Used for packaging, automotive bumpers/interiors, medical devices, piping, hinges, containers, textiles (nonwoven) and household goods.

Polypropylene copolymer (random or block) — better impact resistance at low temperatures than PP homopolymer (PP-H). Random copolymer: excellent clarity for packaging. Block copolymer: high impact for automotive bumpers, containers, and household appliances. Trade names: Moplen (LyondellBasell), Hostalen (LyondellBasell). THE automotive interior/exterior polymer alongside ABS.

Polypropylene Homopolymer — the lightest common engineering plastic (0.905 g/cm³). Excellent chemical resistance (esp. to acids and bases), good fatigue resistance (integral living hinges), and low moisture absorption. Becomes brittle below 0°C. Used for chemical tanks, HVAC ducts, pump housings, food containers, automotive battery cases, and medical lab equipment.

Chlorinated Polyvinyl Chloride — PVC with additional post-chlorination (chlorine content raised from 57% in PVC-U to 63-69% in CPVC). This significantly raises the Vicat softening temperature and glass transition, extending the service temperature from ~60°C (PVC-U) to 95-100°C. Retains excellent chemical resistance, flame retardancy (LOI 50-60%), and good mechanical properties. Primary applications: hot water plumbing, industrial chemical piping, fire sprinkler systems, power plant cooling systems, semiconductor wet benches. Major brands: Corzan (Lubrizol), TempRite (Lubrizol), BlazeMaster (sprinklers).

Flexible (plasticized) PVC — PVC compounded with 20–50% plasticizer (typically DEHP, DINP or DOTP) to achieve rubber-like flexibility. Very different properties from rigid PVC-U. Excellent electrical insulation, chemical resistance, flame retardancy (self-extinguishing) and weatherability. Trade names: Vestolit P (Orbia), Geon (Polyone). Used for cable insulation and sheathing, medical tubing, automotive interior trim, inflatable products, floor coverings, hoses and sealing profiles. Continuous use -30°C to +70°C.

Unplasticized Polyvinyl Chloride — the second-most produced plastic globally. Hard, rigid, self-extinguishing (LOI 45%), excellent chemical resistance to acids/bases/salts, and very low cost. Key limitation: max service temp only 60°C. Developed in 1930s Germany. Used for water/sewage pipes, window profiles, electrical conduit, cladding, and chemical tanks/fittings. NOT the flexible PVC used in cables — that is PVC-P (plasticized).

Styrene-acrylonitrile copolymer — AN 20-30% improves chemical resistance, heat resistance, and stiffness vs PS. Transparent (clear). Higher stiffness (E ~3.5 GPa) and HDT than PMMA. Used for housewares, cosmetic packaging, instrument lenses, battery cases, and transparent housings. THE clear engineering-grade styrenic. Also base polymer for ABS (SAN + butadiene rubber).