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Polymers in Medical Devices: Resins Shaping Modern Healthcare

Polymers in Medical Devices: Resins Shaping Modern Healthcare

by | Sep 18, 2023 | Blog

In healthcare, the materials used serve as a vital influence on the quality of care for patients and the costs they pay. Modern medical device manufacturing advancements hinge primarily on the revolution of polymer resins.

Polymer resins are a class of synthetic organic compounds. In manufacturing, it’s polymer resins adaptability for complex shaping that makes them a viable component. As polymer science evolves, the medical industry is increasingly leveraging its power.

Let’s dive deeper into the role of polymer resins in the medical field.

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From PC to Nylon 66: Understanding Polymer Resin Applications in Construction

From PC to Nylon 66: Understanding Polymer Resin Applications in Construction

by | Aug 27, 2023 | Blog

The evolution of construction has an obvious, and essential, relationship with the materials it uses. Throughout history, available materials have shaped the way construction has progressed. From the mud bricks of ancient Mesopotamia to the steel beams of modern skyscrapers, we see it everywhere around us, all throughout history.

Today, we aren’t using mud bricks. Instead, materials such as polymer resins are emerging as materials used to create rigorously strong, safe, and cost-effective construction.

From the durability of Polycarbonate (PC) to the versatility of Acrylonitrile Butadiene Styrene (ABS), polymers offer benefits that many legacy materials can’t compete with.

From the inception of a working construction project to the final touches, we’ll explore how essential polymer resins help us build for a better future.

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Top 5 Benefits of Using Engineering Resins in Electronics Manufacturing

Top 5 Benefits of Using Engineering Resins in Electronics Manufacturing

by | Jul 23, 2023 | Blog

Materials make all the difference, particularly in the competitive electronics industry. If the product’s core suffers from poor quality, design and functionality may falter. And that can lead to poor usability for consumers, and we know where that goes.

Engineering resins are a class of polymers with superior mechanical and thermal properties. The electronics industry leverages engineering resins in numerous and extensive aspects of their manufacturing. 

In today’s blog post, we’ll examine five benefits to using engineering resins in electronics manufacturing. 

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UL Listings

by | May 11, 2023 | Blog

UL 94 Listings

UL 94 is the flammability standard which determines a material’s likelihood to either spread or put out a flame once the material has been lit on fire. The UL 94 testing can present a variety of determinations including hourly fire resistance ratings, surface burning characteristics, roof covering flammability ratings and flammability of contents within a structure. The testing is done on a small scale to evaluate the flammability of the plastic used in various parts under controlled conditions. There are three types of UL 94 ratings we typically use:

HB Rating

  • Samples are place horizontally and ignited
  • The flame must burn slowly across the sample V (V-0, V-1, or V-2) Rating
  • Samples are placed vertically and ignited
  • The flame must extinguish within specific time frames and not drip material

5V (5VA or 5VB) Rating

  • Samples tested both vertically and horizontally
  • The flame must burn slowly across the sample V (V-0, V-1, or V-2) Rating
  • Samples are placed vertically and ignited
  • Five applications, 5 seconds on, 5 seconds off

UL 746B Listings

UL 746B is the standard for long term property evaluations which determines a material’s thermal aging. This test is used to determine the ability for the tested material to retain its properties after extensive exposure to high temperatures. UL 746B includes a variety of components including dielectric, tensile and impact testing. The RTI or relative temperature index is assigned beforehand, based on the material’s specific application. The RTI comparison from before the testing and after is used to determine thermal aging over a period.

There a several types of RTIs given based upon the material application:

  • Electrical RTI
  • Mechanical Impact RTI
  • RTI Elongation
  • Mechanical Strength RTI

UL 746C Listings

UL 746C is the standard for UV and water testing. This type of testing is suitable for materials that are meant to be used in an outdoor application. To test UV, the material is either put into a twin-enclosed carbon weatherometer for 720 hours, or a xenon-arc weatherometer for 1000 hours. To test whether the material can withstand water exposure, it is immersed into water for 7 days at 70°C. There are two types of UL 746C Ratings:

F1 Rating

  • The material has passed both the water and UV testing.

F2 Rating

  • The material has passed either the Water or UV testing but not both
  • The material has only been partially tested

About Polymer Resources

Headquartered in Farmington, Conn., Polymer Resources is a leading, privately owned U.S. supplier of high-quality customized specialty engineering resin compounds, color-matching services and related materials technology solutions for the electrical, medical, consumer goods, business equipment and automotive industries. Operating with an extensive list of UL approved products, it is one of very few polymer suppliers that backs its compounding and color match services with a quality guarantee. The company’s commitment to customer service, financial discipline, and foresight for over 45 years has made it a reliably steady resource for specialty compounds in the often-volatile plastics industry. With operations in Farmington and Rochester, N.Y., Polymer Resources continues to fuel its growth through ongoing investments in its manufacturing assets and its top industry talent. The company’s direct sales force and local warehousing throughout the United States enable on-time delivery and fast, local customer service anywhere in the country.

For more information, visit www.prlresins.com

Structural Foam Molding – Working with Complicated Designs

Structural Foam Molding – Working with Complicated Designs

by | Dec 19, 2019 | Blog

For products which require a softer inner core and a hard outer surface, Structural foam molding guarantees tough and reliable wall sections. This type of molding process is generally used for medium to high volume production and produced on injection molding machines where a foaming agent is used to produce thick internal wall sections.

Depending on the processing method and the application, there are wide varieties of Polycarbonate plastic available in the market. There are different blends of Polycarbonate PC like ABS, Polyesters etc. which are normally used in the automotive industry. There are various processing methods associated with Polycarbonate which includes Injection molding, Vacuum forming, Extrusion, Structural foam molding and Blow molding.

Typically used for applications or products where the goal is to reduce the component weight and tension in the material needs to be avoided, Structural foam molding allows the designer to work easily with complicated designs because the material thickness can be varied between 4 and 10 mm, allowing for diverse designs. A high level description of the structural foam molding process includes use of an injecting propellant which creates the material structure with consistent shape and design throughout the product.

Among several advantages associated with Structural foam molding, one of the most interesting aspects is its ability to make lightweight yet extremely durable and strong products. However, one also needs to be aware that the product surface needs to be painted for a better visual appearance. The superior strength to weight ratio and the use of low pressure allows a wide range of flexible and complex designs, thereby making this process extremely popular.

The process involves use of a small amount of chemical blow agent inside the plastic material which makes the internal walls thicker. When the melted plastic gradually enters the mold cavity, foaming would create a plastic wall that solidifies into a great molding wall. This versatile process can be easily used with any thermoplastic which can be injection molded. The large plastic products have a solid skin and a cellular inner structure while keeping the weight lower which makes it a favorite for vehicles, sports equipment and aircraft.

The Process

Structural foam molding needs Nitrogen to be injected into the melt before it is injected into the mold. Once the solid wall is created, the core is retracted so that the pressurized gas can expand and create a uniform cellular structure. Used with most thermoplastic materials, the process allows for weight reduction without compromising on its high rigidity features. The molded material doesn’t warp and also there are no sink marks because of the dense skin and rigid core.

The dimensional stability and high impact strength allows for great processing flexibility. The structural foam molding process creates molded parts with a smooth and solid surface on the outside and a foam structure on the inside.