
Hard plastics are used in a wide range of applications, from medical inhalers to automotive parts and machinery enclosures. They are known for their strength, durability, and resistance to high temperatures. There are several types of hard plastics, including polycarbonate, polyethylene, polypropylene, and polyvinyl chloride (PVC). Each type of hard plastic has unique properties that make it suitable for specific applications. For example, polycarbonate is known for its optical clarity and impact resistance, while polyethylene can be manufactured in varying densities, giving it unique physical properties for different products. Understanding the different types of hard plastics and their characteristics is crucial for product manufacturing and recycling purposes.
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What You'll Learn

Polycarbonate
One of the key advantages of polycarbonate is its ability to undergo large plastic deformations without cracking or breaking. This property sets it apart from most other thermoplastics and allows it to be processed and formed using sheet metal techniques, such as bending, drilling, or routing. It can be cut or cold-formed on-site, making it a convenient choice for prototyping and customisation.
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High-density polyethylene (HDPE)
One of the key advantages of HDPE is its ability to replace heavier materials, making it a cost-effective and environmentally friendly choice for manufacturing and projects. It is commonly used in the production of plastic bottles, especially for oils and liquids, as well as piping, geomembranes, plastic lumber, and corrosion-resistant applications. Its corrosion resistance and chemical resistance make it suitable for industrial pipe networks, chemical storage tanks, safety gear, and outdoor settings where weather resistance is crucial.
In terms of production, HDPE is derived from the monomer ethylene through industrial processes such as the Ziegler-Natta polymerization or the Phillips slurry process. The choice of method impacts the properties of HDPE, with the Phillips Slurry process resulting in less branching and more precise molecular weights, while the Ziegler process offers greater flexibility in the type of polyethylene produced.
HDPE is also known for its recyclability, bearing the number "2" as its resin identification code. This feature further contributes to its environmental benefits by reducing plastic waste in landfills. Additionally, HDPE is used in the pyrotechnics trade for mortars, as it is more durable and safer than steel or PVC tubes, tearing instead of shattering in the event of a malfunction.
Overall, HDPE is a highly versatile, strong, and cost-effective plastic with a wide range of applications, from packaging and construction to industrial and safety equipment. Its unique combination of properties makes it a popular choice across various industries.
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Polyvinyl chloride (PVC)
PVC is formed in flat sheets in a variety of thicknesses and colours. These sheets are often expanded to create voids in the interior of the material, providing additional thickness without extra weight and cost. This process is known as closed-cell PVC foamboard. PVC is also used to produce thin, coloured, or clear, adhesive-backed films, known simply as "vinyl".
PVC is used in a wide range of applications across many sectors, including building and construction, healthcare, electronics, and automobiles. In construction, it is used for pipes, fascia, siding, and weatherboarding. It has almost entirely replaced cast iron for plumbing and drainage, being used for waste pipes, drainpipes, gutters, and downspouts. PVC is also used for door and window profiles, as well as in cladding, roofing, fencing, decking, wall coverings, and flooring.
In healthcare, PVC is used for blood bags, tubing, and medical devices. It plays a critical role in dispensing life-saving medicine and has enhanced ambulatory medicine. PVC is also used for wire and cable insulation, as well as in the packaging of medicines, personal care products, and household goods.
PVC is known for its strong resistance to chemicals, sunlight, oxidation from water, impact, weather, and corrosive environments. It is also durable and fire-resistant, making it a popular choice in construction and industrial applications. However, lead compounds previously added to PVC to improve workability and stability have been shown to leach into drinking water. In Europe, the use of lead-based stabilizers has been discontinued due to health concerns.
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High-impact polystyrene (HIPS)
HIPS is a popular choice for machining pre-production prototypes as it can be guillotine cut, die-cut, punched, and painted or glued. It is also FDA-compliant for use in food processing applications. Printers often choose HIPS for graphics that stay flat and precise, while manufacturers value its compatibility with thermoforming machines for FDA-approved food containers. HIPS is also used as a substrate to mount graphics such as plotter vinyls/films. It is ideal for producing signs and displays, as it is one of the lower-cost materials available.
HIPS combines cost-effectiveness with versatility and impact resistance, making it suitable for a wide variety of industrial applications. Its machinability makes it ideal for drilling, sanding, or painting, and its impact resistance means it can withstand stress without cracking. HIPS is often used as a replacement for heavier materials like wood or metal, reducing shipping costs without compromising protection.
HIPS is an amorphous thermoplastic material, used in lower-heat applications. It offers ease of processing, high impact strength, and stiffness. It is often specified for low-strength structural applications when impact resistance, machinability, and low cost are required.
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Acetal
Food-grade acetal is an FDA-compliant copolymer acetal that is optically detectable and suitable for food contact. It has good mechanical and wear properties and is easy to machine to tight tolerances. Optical, Metal, and X-Ray Detectable Acetal is another FDA-compliant acetal copolymer designed for food contact. This multi-detectable blue plastic can be detected by optical scanners, metal detection equipment, and X-ray detection equipment. It offers good machinability and mechanical properties for applications in the food and pharmaceutical industries.
Delrin® AF DE588 is a grade of homopolymer acetal with 20% PTFE fiber fill. It offers outstanding friction and wear characteristics and is often used for United States Naval equipment. Acetal's ability to withstand temperatures up to 90°C while maintaining its shape, rigidity, and strength makes it suitable for various applications, including dishwashers, car engine components, and electrical components requiring excellent insulating properties.
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Frequently asked questions
Some examples of hard plastics include methacrylate, polycarbonate, PVC, PETG, ABS, polypropylene, polystyrene, nylon, and polyethylene.
Hard plastics are known for their strength, stiffness, and toughness. They have excellent resistance to chemicals, corrosion, and heat. Some hard plastics are transparent, while others are opaque. They can be easily worked, molded, and thermoformed or cold-formed.
Hard plastics are used in a wide range of applications, including automotive interiors, outdoor machinery components, electrical enclosures, medical devices, construction materials, packaging, and consumer goods.
Hard plastics offer several benefits, including low cost, lightweight, durability, impact resistance, and design flexibility. They are also recyclable and can be used as an alternative to glass or metal in many applications.









































