Thermoplastic Material Selection – A Practical Guide

Thermoplastic Material Selection – A Practical Guide
Eric R. Larson
Table of Contents

1. Introduction
   1.1. The Stone Age
   1.2. The Age of Metals
   1.3. Other Materials
   1.4. The Industrial Revolution
   1.5. Mass Production
   1.6. Materials Science
   1.7. The Plastics Age
   1.8. Plastics—The Other Synthetic Material
   1.9. Plastics Material Selection
   1.10. How This Book Can Help You
2. Why Use Plastic?
   2.1. Introduction
   2.2. Plastics as Raw Materials
   2.3. Plastic Processing Technologies
   2.4. Process Comparison
   2.5. Plastics in Manufacturing
   2.6. Advantages of Thermoplastics
   2.7. Disadvantages of Thermoplastics
   2.8. The Uniqueness of Thermoplastics
   2.9. And the Answer Is…
3. Understanding Thermoplastics
   3.1. Introduction
   3.2. Materials Science
   3.3. Polymer Science
   3.4. The Resin Industry
   3.5. Thermoplastic Classification Methods
   3.6. A Final Word about Property Data
   3.7. The Amazing World of Thermoplastics
4. An Overview of Thermoplastic Materials
   4.1. Key Thermoplastic Materials
   4.2. Thermoplastic Elastomers
   4.3. Meet the Family
5. Material Selection Based on Performance
   5.1. What is Performance?
   5.2. Predicting Performance
   5.3. How Material Selection Affects Performance
   5.4. Environmental Effects
   5.5. Key Mechanical Properties
   5.6. Measuring Toughness
   5.7. But Is It Tough Enough?
   5.8. Surface Properties
   5.9. Key Electrical Properties
   5.10. Properties of Form
   5.11. Some Final Guidelines
6. Material Selection Based on Cost
   6.1. What is Cost?
   6.2. Why is Cost Important?
   6.3. The Language of Cost
   6.4. Evaluating Cost
   6.5. Reducing Material Costs
   6.6. Reducing Processing Costs
   6.7. Total Manufacturing Cost
   6.8. A Final Word on Cost
7. Material Selection Based on Feel
   7.1. What Is Feel?
   7.2. Why Is Feel Important?
   7.3. The Language of Feel
   7.4. Evaluating Feel
   7.5. Sight
   7.6. Hearing
   7.7. Touch
   7.8. Smell
   7.9. Taste
   7.10. A Methodology
   7.11. A Final Word about Feel
8. Bringing It All Together
   8.1. Material Selection
   8.2. Material Specification
   8.3. The Plastics Supply Chain
   8.4. Industry Infrastructure
   8.5. Working with Suppliers
   8.6. Troubleshooting
   8.7. Finale
   Index
   A
   Acetal, 109–111
   copolymer, 110
   disposable lighters molded from,
   111, 112f
   homopolymer, 110–111
   Acrylic, 98, 106t–107t. See also
   Polymethyl methacrylate
   (PMMA)
   Acrylonitrile butadiene styrene (ABS),
   108–109
   Age of Metals, the, 3–7
   bronze object, 4, 5f
   copper ore, 3, 4f
   iron ore, 4–5, 6f
   Alloys, 86–87
   Amorphous, 66
   versus semicrystalline, 92–93
   Amortization, 213
   B
   Benchmarks, 146
   Bending, 58, 59f, 60
   and stiffness, 61–62, 61f–62f, 166
   Blends, 86–87
   Blow molding, 37
   extrusion blow molding, 37
   injection blow molding, 38
   for plastic bottle, 39f
   preforms, 38f
   Boat anchor (slang), 214
   C
   Cantilevered beam with end load, 153, 153f
   Capital, 213
   Capital asset, 213
   Capital investment, 213
   Cellulose, 13
   Cellulose acetate, 271
   hair barrette made from, 271, 271f
   Ceramics, 7–8
   Charpy test, 171, 172f
   Clays, 7–8
   Commodity plastics, 105, 106t–107t
   acrylic, 98
   ethylene propylene diene monomer
   (EPDM), 102
   polyacrylates, 98
   polyethylene (PE). See
   Polyethylene (PE)
   polymethyl methacrylate (PMMA),
   98–100, 116
   polypropylene (PP).
   See Polypropylene (PP)
   polystyrene (PS), 102–103
   polyvinyl chloride (PVC), 103–104
   thermoplastic polyurethane (TPU), 105
   Compression, 58, 59f, 165, 165f
   Compression molding, 31
   antique waffle iron, 31, 31f
   Conductive plastics, 191
   Copolymer, 64–66, 110
   Correlation
   correlation model, 148, 148f
   in predicting performance, 148–149
   Cost of goods, 213
   Costs, 207–209, 208f
   evaluating, 214–219
   adding up numbers, 219
   cycle times, 217–219
   material cost, 215–216
   process rates, 216–217, 218t
   processing cost, 216
   importance of, 209–212
   bottom line on cost, 211–212, 211f
   business perspective, 210–211
   measuring cost, 210
   relationship to performance, 210
   language of, 212–214
   reduction. See Material costs, reducing;
   Processing cost, reducing
   in thermoplastic material selection, 208
   Note: Page numbers followed by “f” and “t” indicate figures and tables respectively.340 Index
   Cracking, 151
   initiation and propagation, 168
   Critical material properties, 203
   Cross-linking process, 23–24
   D
   Design, 214
   D F X (design for initiative),
   230–231
   importance of, 152–154
   options, and manufacturing
   costs, 243
   for speed, 241–242
   Drop testing, 174–175, 175f
   E
   Elastic deformation, 58–59
   Elastic modulus, 60–61
   Electrical impulses, in sensing
   sound, 273, 275
   smell, 293–294
   taste, 300
   touch, 282
   Electrical properties, 191
   conductive plastics, 191
   insulating plastics, 191
   Electromagnetic waves, 160
   spectrum, 161f
   Engineering plastics, 108–119,
   119t–120t
   acetal, 109–111. See also Acetal
   acrylonitrile butadiene styrene (ABS),
   108–109
   polyamide. See Polyamide (PA)
   polyester, 116–118
   polyethylene terephthalate,
   116–117
   polyphenylene oxide (PPO),
   118–119
   Ethylene propylene diene monomer
   (EPDM), 102, 137
   Ethylene tetrafluoroethylene (ETFE),
   125–126
   Expandable foam molding, 36
   coffee cups, 36, 36f
   Extrusion, 29–30
   extruded drinking straws, 29f
   Extrusion blow molding, 37
   F
   Failure mode and effects analysis
   (FMEA), 199
   Feel, 251–253
   evaluating, 265–266
   human senses, 266. See also Human
   senses, in evaluating feel
   physical equipment, 266
   importance of, 253–256
   product performance, 253–254
   language of, 256–265, 258f
   comparative analysis, 265, 265f
   human response, 259–263, 260f, 262f
   imprecise language, 264
   non-engineering, 263–264, 264f
   sensory input, 257–259
   sales and market share, 254–255, 255f
   bottom line on feel, 256
   technical validity, 255–256
   thermoplastic material selection,
   methodology, 302–307
   flow chart based on feel, 306, 307f
   infrastructure, 303–304
   process, 304–306
   suggestions, 306–308
   touch, 251–252, 252f–253f
   Flammability, 160
   Flexural modulus, 61, 61f, 166–167
   Flexural strength, 61, 61f
   Fluorinated ethylene propylene (FEP),
   126, 134t–135t
   Fluoropolymers, 124–125, 134t–135t.
   See also Fluorinated ethylene
   propylene (FEP); Perfluoroalkoxy
   alkane (PFA)
   Foam molding
   expandable, 36
   structural, 35–36
   Fordism, 10
   Form properties, 192–197
   appearance, 195–197
   material samples, standard colors of,
   196–197, 197f
   shape, 194–195
   size, 192–194
   Herman Miller Equa chair shell, 192,
   193f
   micromolding, 194, 194f
   Fracture mechanics, 168Index 341
   G
   Gamma rays, 161–162
   Gardner impact testing, 172–173
   Glass, 7–8
   Glass transition temperature, 67–68
   H
   Hardness, 289–291
   data comparison, 290, 290f
   Heat deflection temperature
   (HDT), 156, 199
   High-speed tensile tests, 173–174
   Homopolymer, 64–66, 110–111
   Housings, in Apple products, 45–46
   Human senses, in evaluating feel, 266
   hearing, 273–279
   acoustics, 274–275
   human response, 277
   material selection based on,
   277–279, 279f
   music, 276–277
   opportunities, 279
   psychoacoustics, 275–276
   sheet music, 276, 277f
   sound, 273–274
   sound waves, 273–274, 274f
   vibrations, 274
   sight, 266–273
   color, 269–270, 270f
   light, 267–269
   material selection based on,
   271–273, 272f
   opportunities, 273
   optical data, 267, 268t
   patterns, 270–271, 271f
   smell, 293–299, 294f
   human brain, 294–295, 295f
   human response to odor, 298
   material selection based on, 299
   new car smell, 297, 297f
   odor detection, 294–296
   odor in thermoplastics, 296–298
   opportunities, 299
   taste, 300–302
   material selection based on, 301–302
   opportunities, 302
   touch, 279–293
   hardness, 289–291
   material selection based on, 292–293
   movement, 287–289, 289f
   opportunities, 293
   pressure, 286
   size and shape, 280
   slipperiness, 291–292, 292f
   temperature, 282–286
   texture, 291
   vibration, 286–287
   weight and density, 280–282,
   281f–282f
   Hydroslide, 180
   I
   Industrial Revolution, 8–10
   Aubin forging mills, 8–9, 9f
   Industry infrastructure,
   317–320
   education, 318–319
   information providers, 319
   plastic testing, 319
   service providers, 319–320
   trade organizations, 318, 318f
   Injection blow molding, 38
   Injection molding, 32–33, 213
   different screws for, 32–33, 33f
   reaction injection molding, 34
   Instrumented impact tests, 173
   Insulating plastics, 191
   Izod test, 170
   schematic diagram of pendulum test,
   170, 171f
   J
   Job production, plastics
   manufacturing, 44
   K
   Kevlar® (aramid fiber), 122–123
   L
   Leaf blower, 181, 181f
   Liquid crystal polymer (LCP),
   126–127
   multipin connectors molded
   from, 127f
   M
   Mass production, 10–11
   Material cost, 213342 Index
   Material costs, reducing, 219–230
   effective specifications, 222–224
   exploiting competitive advantages,
   227–229
   Ethafoam®, 229
   Mach 7 product line, 229, 230f
   SRAM IBS shifters, 227–228, 227f
   Surlyn®, 229
   exploiting material, 224–226
   BIC lighters, 225, 225f
   Fresnel lens, 226, 226f
   optimizing structure, 220–222
   five-legged office chairs,
   220, 221f
   optimizing wall thickness, 224
   reducing processing cost, 230–242.
   See also Processing cost, reducing
   Material properties effects analysis
   (MPEA), 200, 201t–202t
   Material selection, 311–313
   based on
   hearing, 277–279, 279f
   sight, 271–273, 272f
   smell, 264
   taste, 301–302
   touch, 292–293
   data, evaluating, 312–313
   development, 313
   environmental effects, 156–164
   chemicals, 159–160
   four horsemen of plastic apocalypse,
   157, 157f
   radiation, 160–162
   temperature, 158–159
   time, 162–164
   infrastructure. See Industry
   infrastructure
   key criteria, establishing, 312
   manufacturing process,
   selecting, 312
   material candidates, list
   developing, 312
   material, selecting, 313
   opportunities
   hearing, 279
   sight, 273
   smell, 264
   taste, 302
   touch, 293
   and performance, 150–156, 151f
   design, importance of, 152–154, 153f
   processing, importance of, 154–155
   property data. See Property data
   specification of. See Material
   specification
   supply. See Supply chain, plastics
   Material selection and cost, 207–250
   costs, 207–209, 208f. See also Costs
   evaluating, 214–219
   importance of, 209–212
   language of, 212–214
   reducing costs. See Material costs,
   reducing; Processing cost,
   reducing
   in thermoplastic material selection,
   208
   total manufacturing cost, 243–247. See
   also Total manufacturing cost
   Material specification, 313–315
   approved suppliers, 314–315
   Materials science, 3, 11–12, 58–64
   anisotropic behavior, 60–61
   nonlinear behavior, 62
   professional societies, 12
   role of chemistry in, 8
   stiffness, 62–63, 62f
   strength of materials, 58–60
   stress–strain curves, 59, 59f
   types of load, 58, 59f
   toughness, 63–64, 63f. See also
   Toughness
   Mechanical properties, 164–170
   stiffness, 166–167
   strength, 164–166
   types of loads, 165, 165f
   toughness, 167–170. See also
   Toughness
   Melt cycle, 69
   Melt temperature, 68
   Melting temperature, 68
   Model T, 10
   factory, 11f
   Molding, 25
   blow molding. See Blow molding
   closed mold, 26f
   compression molding, 31
   foam molding. See Foam molding
   injection molding. See Injection moldingIndex 343
   open mold, 25f
   plastic molding, 30
   rotational molding, 32
   transfer molding, 34–35
   Molecular weight, 68
   distribution, 68
   Moment of inertia, 153
   Monomers, 64
   propylene monomer, 65f
   N
   Nomex® (aramid fiber), 122
   Noryl®, 119
   Notch sensitivity, 168
   window glass, 168f
   Nylon (polyamide), 13, 112, 184
   amorphous nylon, 114
   nylon 11, 114
   nylon 12, 114
   nylon 6, 113
   nylon 6/10, 113
   nylon 6/12, 113
   nylon 6/6, 113
   effects of oven aging on, 162, 163f
   hose mender parts, molded from,
   326, 327f
   nylon chemistry, 114
   parachute, 14f
   O
   Odor
   human response to, 298
   in thermoplastics, 296–298
   Off-spec, 77, 77f
   Optical data, 267, 268t
   Optical grade, 77
   Optimization
   for reducing material costs
   of structure, 220–222
   of wall thickness, 224
   for reducing processing costs, of
   geometry, 231–233
   P
   Paleoanthropology, 1–2
   PBS NOVA program, 5–6
   Perfluoroalkoxy alkane (PFA), 126
   Performance, 145–147, 147f
   and material selection, 150–156, 151f.
   See also Material selection
   design, importance of, 152–154,
   153f
   processing, importance of, 154–155
   property data. See Property data
   predicting, 147–150
   correlation, 148–149
   disruptive innovation, 149–150
   wrong criteria, 149
   Phono preamplifier with tubes, 278,
   279f
   Physiology, context of sound, 275
   Plastic Age, the, 12–14, 17
   Plastic behavior, 19, 19f
   Plastic deformation, 19, 58–59
   Plastic processing technologies, 24–38
   blow molding, 37
   casting, 30–31
   compression molding, 31
   expandable foam molding, 36
   extrusion, 29–30
   extrusion blow molding, 37
   injection blow molding, 38
   injection molding, 32–33
   plastic molding, 30
   plastic welding, 28–29
   plastics forming, 26
   plastics tooling, 25
   pressure forming, 27–28
   process comparison, 39
   common processing techniques, 39,
   40t–41t
   reaction injection molding, 34
   rotational molding, 32
   structural foam molding, 35–36
   transfer molding, 34–35
   vacuum forming, 26–27
   Plastics, 1, 12, 14–15, 20
   in manufacturing, 42–46
   batch production, 43–44
   job production, 44
   manufacturing processes, 44–46
   mass production, 42–43
   market use, 70, 71f
   material selection, 15–16
   processing technologies, 24–38. See also
   Plastic processing technologies
   as raw materials, 20–24
   thermoplastics. See Thermoplastics
   thermosets. See Thermosets344 Index
   Plastics, academia
   Auburn University, 335
   Ferris State University, 336
   Lehigh University, 336
   Pennsylvania College of Technology, 336
   Erie-Behrend College, 336
   Stevens Institute of Technology, 336
   University of Akron, 336
   University of Massachusetts
   Amherst, 337
   University of Massachusetts Lowell, 337
   University of Southern Mississippi, 337
   University of Tennessee, 337
   University of Wisconsin, 337
   Plastics publications
   Plastics Business (magazine), 331
   Plastics Engineering (magazine), 331
   Plastics News, 331
   Plastics Technology (magazine), 331
   Plastics technology, 13–14
   Plastics tooling, 25
   Plastics websites
   plastics.com, 332
   plasticsguy.com, 332
   Polyacrylates, 98
   Polyamide (PA), 111, 114
   cable tie, 115f
   polyamide 11, 114
   polyamide 12, 114
   polyamide 6, 113
   polyamide 6/10, 113
   polyamide 6/12, 113
   polyamide 6/6, 113
   Polyamide-imide (PAI), 129
   Polyarylate (PAR), 127
   Polybutylene terephthalate (PBT),
   116–118
   hot melt glue gun, 118, 118f
   Polycarbonate, 115, 184
   football helmet, 148–149
   modern fighter jets, 116f
   Polycyclohexylenedimethylene
   terephthalate, 117
   Polyester block copolymers (PBC),
   138–139
   constant-velocity (CV) joint, 139, 139f
   Polyester, 116–118
   Polyether-block-amide elastomer, 140
   Polyetherimide (PEI), 129
   Polyethersulfone, 133
   Polyethylene (PE), 100–102
   bubble wrap packaging, 101, 101f
   polymers, 100–101
   Polyethylene terephthalate (PET), 116–118
   hot melt glue gun, 118, 118f
   Polyethylene terephthalate, 116–117
   Polyimide (PI), 128–129
   flexible printed circuits, 128f
   Polyketone (PK), 130
   Polymer molecule, 20, 20f
   Polymer science, 64–69
   amorphous, 66
   crystallinity, 66
   molecular model of, 67f
   crystallization, 66–67
   glass transition temperature, 67–68
   melt cycle, 69
   melt temperature, 68
   melting temperature, 68
   molecular weight, 68
   distribution, 68
   polymer chemistry, language, 65f, 66
   resin, 66
   Polymerization, 64
   Polymers, 12–13
   and monomers, 64
   polypropylene polymer, 65f
   Polymethyl methacrylate (PMMA),
   98–100, 116
   in aquariums, 100, 100f
   Polymethylpentene (PMP), 130
   laboratory glassware, 131f
   Polyolefin blend elastomers (POE),
   137–138
   Polyphenylene oxide (PPO), 118–119
   Polyphenylene sulfide (PPS), 130–131
   Polyphenylsulfone, 133
   Polyphthalamide (PPA), 131–132, 132f
   Polypropylene (PP), 102
   copolymer, 102
   block copolymer, 102
   impact-modified copolymer, 102
   random copolymer, 102
   recycling bin molded from, 102, 103f
   homopolymer, 102
   monomer of, 123fIndex 345
   Polystyrene (PS), 102–103
   CD cases made from, 103, 104f
   Polysulfone (PSU), 132–133
   Polytetrafluoroethylene (PTFE), 124–125
   thread sealing tape made from, 125, 125f
   Polytrimethylene terephthalate (PTT), 117
   Polyvinyl chloride (PVC), 103–104
   vinyl LP records, 104f
   Polyvinylidene fluoride (PVDF), 126
   Pressure forming, 27–28
   used in conjunction with vacuum, 27, 28f
   Processing cost, 213
   Processing cost, reducing, 230–242
   design for speed, 241–242
   effective specifications, 233–237
   parts and assembly, 237, 238f
   precision and price, 234, 235f
   exploiting materials, 239–241
   optimizing geometry, 231–233
   uniform wall thickness, 238–239
   chair base design, 239, 240f
   Professional societies
   American Chemical Society
   (ACS), 332
   American Society of Mechanical
   Engineers (ASME), 332
   SAE International, 332
   Society for the Advancement of
   Material and Process Engineering
   (SAMPE), 333
   Society of Plastics Engineers
   (SPE), 333
   Blow Molding Division, 333
   Thermoforming Division, 333
   Projectile testing, 174
   Property data, 155–156
   evaluation, 152
   Psychology, and perception, 276
   Q
   Qualitative analysis, 176
   Quantitative analysis, 199–200
   R
   Radiofrequency (RF) spectrum, 161
   Rates
   cost rates, 217, 218t
   process rates, 216–217
   Reaction injection molding (RIM), 34
   Resin, 66
   Resin industry, 69–90
   alloys and blends, 86–87
   oil and vinegar blend, 86, 87f
   fillers, 82
   performance modifiers, 83–84
   processing aids, 81–82
   reinforcements, 82–83
   glass fiber “chopped strands”, 83, 83f
   resin distribution, 71–75
   bag, 72, 73f
   boat load, 74
   bulk box, 72, 73f
   railcar, 72–74, 74f
   truckload, 72
   resin grades, 75–79
   food grade, 75, 76f
   generic prime, 75, 76f
   industrial, 77
   medical grade, 76
   off-spec, 77, 77f
   optical grade, 77
   postconsumer waste, 78
   preconsumer waste, 78
   prime, 75
   recycled, 77–78, 78f
   regrind, 78
   reprocessed, 77
   virgin, 78, 79f
   resin modification, 79–81
   compounding, 80
   cube blending, 80, 81f
   dry blending, 80–81
   melt blending, 80
   resin production, 70–71
   resin versions, 84–86
   Risk priority number (RPN), 199
   Rotational molding, 32
   molded parts, 32, 32f
   S
   Semiotics, 276
   Sensation, touch, 251–252, 252f–253f,
   279–293
   hardness, 289–291
   material selection based on, 292–293
   movement, 287–289, 289f346 Index
   Semiotics (Continued)
   opportunities, 293
   pressure, 286
   size and shape, 280
   slipperiness, 291–292, 292f
   temperature, 282–286
   texture, 291
   vibration, 286–287
   weight and density, 280–282,
   281f–282f
   Shear, 58, 59f, 165, 165f
   Smell, 293–299, 294f
   material selection based on, 299
   odor
   detection, 294–296
   human brain, 294–295, 295f
   human response to, 298
   new car smell, 297, 297f
   in thermoplastics, 296–298
   opportunities, 299
   aroma of freshly molded plastics,
   299, 299f
   Sound, 273–274
   sociology, 276
   sound waves, 273–274, 274f
   reception of, 273–275
   transmitted by tuning fork, 287f
   Specialty plastics, 134t–135t, 122–133,
   134t–135t
   aramid, 122
   speaker cone fabricated from, 124f
   fluorinated ethylene propylene
   (FEP), 126
   fluoropolymers, 124–125
   liquid crystal polymer (LCP), 126–127
   perfluoroalkoxy alkane (PFA), 126
   polyamide-imide (PAI), 129
   polyarylate (PAR), 127
   polyetherimide (PEI), 129
   polyethersulfone, 133
   polyimide (PI), 128–129
   polymethylpentene (PMP), 130
   polyphenylene sulfide (PPS), 130–131
   polyphenylsulfone, 133
   polyphthalamide (PPA), 131–132, 132f
   polysulfone (PSU), 132–133
   polytetrafluoroethylene (PTFE),
   124–125
   polyvinylidene fluoride (PVDF), 126
   ultrahigh molecular weight
   polyethylene (UHMWPE), 133
   Specification, 223
   effective, 233–237. See also Material
   specification
   Sporting goods, 185–186
   SRAM (manufacturer), 185–186
   Shupe test, 187–188
   Standards organizations
   American National Standards Institute
   (ANSI), 333
   ASTM International (ASTM), 334
   International Organization for
   Standardization (ISO), 334
   Underwriters Laboratories (UL), 334
   Stiffness, 62–63, 153, 166–167
   versus weight, 47
   to withstand bending, 23f, 25f, 61–62
   Stiffness factor, 153–154
   Stone Age, the, 1–3
   sample of early stone tools, 1–2, 2f
   Structural foam molding, 35–36
   trash receptacle, 35, 35f
   Stryofoam™, 103
   Styrene
   ABS, 108–109
   monomer of, 123f
   Styrene acrylonitrile (SAN), 104–105
   Styrenic block copolymers (SBC), 136
   Suppliers
   approved, 314–315
   working with, 320–322
   communication, 322
   determining capabilities, 320–321
   determining right fit, 321
   managing relationship, 322
   project participation, 321
   Supply chain, plastics, 315–317, 315f
   compounders, 316
   converters, 316
   equipment suppliers, 316
   product manufacturers, 317
   resin suppliers, 316
   toolmakers, 317
   Surface properties, 188–190
   friction, 189
   hardness, 190Index 347
   lubricity, 189–190
   wear, 190
   Synthetic materials, 13–15
   man-made materials, 55
   T
   Taste, 300–302
   material selection based on, 301–302
   taste of plastic, 301, 301f
   opportunities, 302
   edible plastics, 302, 302f
   Tear resistance, 168, 169f
   Teflon®, 1, 101
   Tension, 58, 59f, 165, 165f
   Terpolymer, 64–66
   Thermal conductivity coefficient (TCC),
   282, 284–286
   of metal horseshoe, 285, 285f
   of plastics and other materials,
   283t–284t
   Thermoforming, 126–127, 139, 155
   Thermoplastic classification methods,
   90–94
   amorphous versus semicrystalline,
   92–93
   chemical family, 93
   cost versus performance, 93–94
   elasticity, 94
   tree of life, 91f
   Thermoplastic elastomers (TPEs), 97–98,
   135–140
   collage of items made from, 135f
   elastomeric alloys, 138
   iDive housing, 137, 137f
   polyamide elastomers, 139
   polyester block copolymers (PBC),
   138–139
   polyether-block-amide elastomer, 140
   polyolefin blend elastomers (POE),
   137–138
   styrenic block copolymers
   (SBC), 136
   Thermoplastic materials, 97–133,
   311–312
   commodity plastics, 98–105
   examples of products, 97–98, 99f
   engineering plastics, 108–119. See also
   Engineering plastics
   industry infrastructure. See Industry
   infrastructure
   material selection. See Material
   selection
   price–performance–volume chart, 97,
   98f
   specialty plastics, 122–133. See also
   Specialty plastics
   troubleshooting, 322–328
   origin, determination, 324–326
   problem solving, 328, 329f
   real problem identification, 323–324
   team assembling, 323
   understanding root cause, 327–328
   Thermoplastic materials, guidelines,
   197–203
   critical material properties, 203
   manufacturing team, 198
   mathematical tools, 199–200
   Thermoplastic polyurethane (TPU), 105
   automotive dashboards, 105
   Thermoplastic vulcanizates (TPV). See
   Polyolefin blend elastomers (POE)
   Thermoplastics, 21–22
   advantages of, 46–49
   cost, 48–49
   near-net-shape manufacturing, 47
   performance, 46–47
   processing options, 47
   safety, 48
   disadvantages, 49–55
   heat resistance, 49
   human behavior, 54–55
   perception, 53–54
   repairing broken parts, 52, 53f
   structural inconsistencies, 51–52
   temperature variations, 51
   time-dependent behavior, 49–50, 50f
   and thermosets, 22–24
   uniqueness of, 55
   Thermosets, 21
   common examples of, 23, 23f
   and thermoplastics, 22–24
   3D printing, 46
   Timber, 7
   Tooling, 213
   Tooling maintenance, 214
   Tooling ownership, 214348 Index
   Torsion, 58, 59f
   Total manufacturing cost, 243–249
   calculating, 243–244, 245t–246t
   flow chart to, 247, 248f
   explore design options, 243
   inspiration in products, 248–249, 249f
   math of, 243–247
   Toughness, 167–170
   bottom line on, 188, 189f
   chew toys, 168, 169f
   crack initiation and propagation, 168
   fracture mechanics, 168
   measuring, 170–176
   Charpy test, 171, 172f
   comparing tests, 177t–178t
   drop testing, 174–175, 175f
   Gardner impact testing, 172–173
   high-speed tensile tests, 173–174
   instrumented impact tests, 173
   Izod test, 170
   projectile testing, 174
   tumble testing, 175–176
   un-notched Izod test, 171
   velocity comparison, 179t
   notch sensitivity, 168
   window glass, 168f
   sudden impact, 167, 167f
   tear resistance, 168
   Trade organizations, 318
   American Mold Builders Association
   (AMBA), 334
   Association of Rotational Molders, 335
   in plastic industry, 318f
   PlasticsEurope, 334
   Society of the Plastics Industry (SPI), 334
   Trade shows
   K Trade Fair, 335
   National Plastics Expo (NPE), 335
   Pacific Design & Manufacturing
   Show, 335
   Transfer molding, 34–35
   Troubleshooting, 322–328
   origin, determination, 324–326
   plastic project, pillars of,
   324, 325f
   problem solving, 328, 329f
   real problem identification, 323–324
   team assembling, 323
   understanding root cause,
   327–328
   Tumble testing, 175–176
   U
   Ulfberht swords, 5–6, 6f
   Ultrahigh molecular weight polyethylene
   (UHMWPE), 133
   Un-notched Izod test, 171
   UV light, 160–162
   V
   Vacuum forming, 26–27
   blister pack, 26–27, 27f
   Valve amplification, 261
   assortment of vacuum tubes, 261f
   Vibration, 286–287
   transmitted by tuning fork, 287f
   W
   Water (H2O), 159–160
   Wood, 7
   X
   X-rays, 160
   Y
   Yield rate, 243–244
   Young’s modulus, 60
   Z
   Zippers, high-performance, 184

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