Materials database

Carbon fiber reinforced epoxy — the benchmark structural composite material. Unidirectional ply: tensile strength 1500–2000 MPa, modulus 120–150 GPa at density 1.55 g/cm³ (5x stronger than steel at 1/5 the weight). Quasi-isotropic layup: UTS ~600 MPa, E ~50 GPa. Autoclave-cured prepreg (aerospace) or infusion/RTM (industrial). Used in aerospace primary structures (fuselage, wings), Formula 1 chassis, bicycle frames, wind turbine blades, pressure vessels (Type IV) and high-end sporting goods. Fiber types: T300, T700, T800, M40J, M55J.

Liquid Crystal Polymer — self-reinforcing aromatic polyester with outstanding flow into thin walls (<0.2mm). Extremely low moisture absorption (0.02%), minimal warpage, excellent dimensional stability. Near-zero creep. Inherently flame-retardant (V-0 at 0.2mm). Very high HDT (>270°C). Trade names: Vectra (Celanese), Zenite (DuPont), Siveras (Toray). THE micro-connector and SMT-reflow-compatible polymer. Used for SMD connectors, fiber optic ferrules, chip carriers, sensors, and ultra-thin-wall electronic housings.

Polyamide 9T — semi-aromatic PA based on 1,9-nonanediamine and terephthalic acid. Lowest moisture absorption of any semi-crystalline polyamide (<0.3% at 50% RH). Tm 300-310°C, excellent dimensional stability. Kuraray exclusive: Genestar. Superior to PA6T in processability (lower Tm) while maintaining high-temp performance. Used for SMT connectors (reflow-compatible), automotive ECU housings, LED reflectors, and precision mechanical parts requiring minimal moisture-induced dimensional change.

PEEK with 30% short carbon fiber — the stiffest and strongest injection-moldable thermoplastic compound available. E-Mod ~24 GPa (vs 11 GPa GF30, 4.1 unfilled). UTS ~212 MPa. Electrically conductive (antistatic/EMI shielding). Outstanding wear/friction properties. Trade names: Victrex 450CA30, TECAPEEK CF30 (Ensinger), KetaSpire CF30 (Solvay). Used for semiconductor wafer handling, bearing cages, compressor components, and metal-replacement structural parts.

PEEK with 30% short glass fiber reinforcement. Dramatically increased stiffness (E-Mod 11 GPa vs 4.1 unfilled) and strength (UTS 160 vs 100 MPa) with reduced elongation and creep. Maintains PEEK's chemical resistance and high-temp capability (continuous 250°C). Trade names: Victrex 450GL30, TECAPEEK GF30 (Ensinger), KetaSpire GF30 (Solvay). Used for structural brackets, pump housings, valve seats, bearing cages, and semiconductor wafer handling where higher stiffness than unfilled PEEK is needed.

PEEK compound optimized for tribological applications — typically PEEK + 10% PTFE + 10% graphite + 10% carbon fiber. Extremely low coefficient of friction (0.15–0.25 vs 0.40 for unfilled PEEK), very low wear rate, excellent PV-limit. Maintains performance at temperatures up to 260°C. Trade names: Victrex HPV (Victrex), TECAPEEK PVX (Ensinger), Ketron HPV (Mitsubishi Chemical). Replaces bronze, Babbitt and other metallic bearings. Used for bushings, thrust washers, seal rings, compressor parts, pump wear rings and sliding components in food/pharma/oil&gas.

Polyetherimide — high-performance amorphous thermoplastic. Similar properties to PEEK at lower cost but lower impact strength and use temp. Transparent amber color. Tg 217°C, inherent flame resistance (UL94 V-0 at 0.4mm), very low smoke. Hydrolytically stable (2000+ autoclave cycles). Trade name Ultem (SABIC). Used for aerospace interior panels, medical sterilizable devices, electrical insulators, semiconductor handling, and 3D-print build plates.

Polyetherimide with 30% glass fiber — Ultem 2300 (SABIC). 2x the stiffness of unfilled PEI (E-Mod 9.5 vs 3.3 GPa) with UTS ~155 MPa. Retains PEI's inherent flame retardance (V-0), chemical resistance, and high Tg (217°C). Reduced elongation (3% vs 60% unfilled). Used for structural aircraft interior brackets, electrical connector housings, under-hood automotive, and medical device components requiring rigidity + flame retardance.

Polyethersulfone — an amorphous high-performance thermoplastic from the sulfone family (PSU/PES/PPSU). Highest continuous service temperature among standard sulfones (up to 180°C), glass transition 220°C. Transparent amber color, excellent dimensional stability, hydrolytic stability even under steam sterilization (>1000 cycles). High mechanical strength maintained at elevated temperatures. Commercialized in 1972 by ICI and 3M. Typical applications: aerospace interior components, membrane filters (ultrafiltration), medical sterilizable devices, hot water fittings, battery components, electronic connectors, food service equipment.

Polyimide — THE extreme-temperature polymer. Continuous use 250-300°C (short-term to 400°C+). Outstanding thermal stability, low outgassing, excellent radiation resistance, and self-lubricating. Available as film (Kapton, DuPont), parts (Vespel, DuPont), and moldable resin. Expensive but irreplaceable where no other polymer survives. Used for aerospace bearings/seals, semiconductor processing, flexible circuit boards (Kapton), jet engine components, and space applications.

Polyphthalamide — semi-aromatic high-performance polyamide. 55%+ aromatic diacid (TPA/IPA) gives Tg ~125°C and Tm >310°C — far above PA66 (Tg 50°C, Tm 260°C). Much lower moisture absorption than aliphatic PAs. SMT-reflow compatible (260°C+). Trade names: Amodel (Solvay/Syensqo), Zytel HTN (Celanese), Ultramid T (BASF), Grivory HT (EMS). Used for automotive powertrain (thermostat housings, charge air coolers), SMT connectors, LED headlamp housings, and metal-replacement applications to 280°C.

Polyphenylene Sulfide — semi-crystalline high-performance thermoplastic. Broadest chemical resistance of any engineering plastic — no known solvents below 200°C. Inherently flame-resistant (V-0 without additives, LOI 44%). Very low moisture absorption (<0.02%). Brittle in unfilled form — usually glass-fiber reinforced for structural use. Trade names include Ryton (Solvay), Fortron (Celanese), Torelina (Toray), Durafide (Polyplastics). Used for chemical pump components, filter bags, electrical insulation, and as base resin for GF40 compounds.

Polyphenylsulfone — highest-performance sulfone polymer. Better impact and chemical resistance than PSU and PEI. Withstands >1000 steam autoclave cycles at 134°C without property loss. Tg 220°C. Transparent amber, colorable. Inherently flame-retardant (V-0). FDA/USP Class VI/ISO 10993 compliant. Trade name: Radel (Solvay/Syensqo), Ultrason P (BASF). Used for reusable medical instrument trays, surgical instrument handles, dental tools, aircraft interior panels, and hot-water plumbing fittings.

Polysulfone — transparent, high-temperature amorphous thermoplastic. Tg 187°C, continuous use to 160°C. Excellent hydrolysis resistance (autoclavable/sterilizable). Good dimensional stability and creep resistance. Positioned between PC (cheaper, lower temp) and PEI (more expensive, higher temp). Trade name: Udel (Solvay). Used for medical devices (sterilizable), hot water plumbing, food processing, membranes (water purification), and aircraft interior panels.