Plastic Materials — Engineering Reference Library (28 Materials)

FedMat stocks 28 thermoplastic and thermoset materials across six categories, from commodity polyolefins to aerospace-grade fluoropolymers and high-pressure laminates. Each material page covers properties, available grades, standard forms and sizes, machining parameters, FDA or compliance status, and head-to-head comparisons against related materials.

How to navigate: Browse by category below, or use the filter callout to match a category to your requirement. Every card links to a full material hub with spoke pages for properties, applications, grades, specifications, machining, FDA compliance, comparisons, and FAQ.

High-Performance Thermoplastics

Materials in this category carry the highest continuous-use temperatures (300–550°F), the best mechanical properties across temperature, and compliance with the strictest aerospace, medical, and semiconductor approvals. They cost more than engineering grades and are the right choice when lower-tier materials would fail.

PEEK (Polyether Ether Ketone) — Continuous use to 480°F, semicrystalline, FDA/USP Class VI. Available in virgin, GF30, CF30, and ELS bearing grades. Used in aerospace bearings, medical implants, semiconductor fixtures, and high-temperature seals.

Ultem / PEI (Polyetherimide) — Amber transparent, continuous use 340°F, UL94 V-0 inherent, autoclavable 2,000+ cycles, FAA-qualified for aircraft interiors. Available in Ultem 1000 and glass-filled 2300.

PAI / Torlon (Polyamide-Imide) — The highest-performing unfilled thermoplastic for structural loads. Continuous use 500°F, requires post-cure for full properties. Torlon 4203 (general purpose), 4301 (PTFE/graphite bearing grade). Used in compressor vanes, thrust washers, and downhole tools.

Polyimide / Vespel (PI) — Continuous use 550°F, short-term to 900°F, no melt point (sublimes). SP-1 unfilled, SP-21 graphite-filled. The most expensive material in the line card — used where no other plastic survives: high-vacuum and extreme-temperature bearing applications.

PPS / Ryton (Polyphenylene Sulfide) — Continuous use 425°F, near-universal chemical resistance below 392°F, 0.02% water absorption, inherently flame retardant. Pump bodies, valve components, and high-temperature electrical housings.

Polysulfone / PPSU (PSU) — Transparent amber, hydrolytically stable. Radel PPSU: 1,000+ steam autoclave cycles at 134°C. Udel PSU continuous 300°F; Radel PPSU 350°F. Medical trays, plumbing fittings, and food-processing equipment.

Engineering Thermoplastics

The workhorses of the line card. These materials balance mechanical performance, chemical resistance, machinability, and cost for the broadest range of industrial applications — gears, bushings, manifolds, wear plates, and structural components.

**Delrin / POM for maximum stiffness and fatigue resistance; POM-C (Acetron GP) for chemical resistance and no centerline porosity. FDA, NSF. Gears, valve seats, manifolds, and bushings.

Nylon (PA 6 / PA 66) — Cast nylon 6 for large-format sizes and low residual stress; extruded nylon 66 for higher stiffness and heat resistance. MoS₂-filled and oil-filled grades extend bearing life. Primary competitor to acetal where impact toughness matters more than dimensional stability.

**PET and PETG (Ertalyte) is the bearing and wear grade — better fatigue and creep resistance than acetal with 0.2% moisture absorption. PETG is amorphous, clear, easily thermoformed. FDA approved. Used in food-zone bushings, manifolds, and thermoformed displays.

**Noryl (Polyphenylene Oxide), max use 220°F, UL94 V-0 available, dielectric strength 500 V/mil. Used in electrical enclosures, fluid-handling housings, and appliance components.

Polyolefin & Commodity Thermoplastics

Low-cost, chemically resistant, and widely used in liners, tanks, ducts, enclosures, and food-contact applications. These materials are easy to fabricate by hot-gas welding and thermoforming.

UHMW (Ultra-High Molecular Weight Polyethylene) — The lowest coefficient of friction of any thermoplastic, abrasion resistance 6× nylon, FDA/USDA approved. Available in virgin, reprocessed, Tivar 1000, and Tivar HPV. Standard liner, wear-strip, chute, and guide-rail material.

HDPE (High-Density Polyethylene) — FDA/USDA approved, UV-stabilized Marine HDPE (Starboard) for outdoor use, density 0.95 g/cc. Easy to thermoform and weld. Cutting boards, marine dock components, and food-processing surfaces.

LDPE (Low-Density Polyethylene) — More flexible than HDPE, FDA approved, density 0.92 g/cc, low-temperature toughness to −100°F. Gaskets, shims, flexible liners, and low-temperature containers.

Polypropylene (PP) — The lightest commodity plastic (density 0.905 g/cc), excellent resistance to acids, bases, and solvents, FDA/USDA approved, weldable by hot gas. Used in chemical tanks, fume hoods, lab fixtures, battery boxes, and ducting.

PVC (Polyvinyl Chloride) — Type 1 PVC for maximum chemical resistance and strength; Type 2 for impact resistance; CPVC for higher temperature (200°F); expanded PVC (Sintra) for signage and display. Cost-effective for chemical ductwork, tanks, and markers.

ABS (Acrylonitrile Butadiene Styrene) — Easy machining and thermoforming, Izod impact 6 ft-lb/in, ABS-FR rated UL94 V-0, paintable. Used in enclosures, housings, thermoformed parts, and prototypes. Primary competitor to polycarbonate where impact strength requirements are moderate.

Fluoropolymers

Fluoropolymers offer the broadest chemical resistance, the lowest surface energy, and high continuous-use temperatures. They are the correct choice for aggressive chemical environments, non-stick surfaces, and high-temperature electrical insulation.

PTFE / Teflon (Polytetrafluoroethylene) — Continuous use 500°F, coefficient of friction 0.05–0.10 (lowest of any solid), inert to virtually all chemicals, FDA approved, dielectric strength 480 V/mil. Filled grades (glass, carbon, bronze, MoS₂) reduce cold flow under load. Seals, gaskets, bushings, and chemical-resistant liners.

PVDF / Kynar (Polyvinylidene Fluoride) — Excellent acid and halogen resistance, continuous use 300°F, higher mechanical strength than PTFE, weldable, inherently flame retardant (UL94 V-0). Used in semiconductor wet-bench components, chemical processing equipment, and high-purity fluid systems.

Transparent Thermoplastics

Where optical clarity is required — machine guards, glazing, displays, signs, and lenses. Polycarbonate leads on impact; acrylic leads on optical clarity and UV stability.

Polycarbonate / Lexan — 250× the impact strength of glass, 30× that of acrylic, optical transmission 88%, continuous use 240°F, UL94 V-2. Machine guards, safety glazing, enclosures, and lenses. Hot-line bend formable without losing clarity.

Acrylic / Plexiglass (PMMA) — 92% light transmission (better than glass), cast acrylic laser-cuts cleanly with flame-polished edges, Rockwell M85–105, no yellowing outdoors over 10+ years. Displays, signs, glazing, and point-of-purchase fixtures where optical perfection matters more than impact resistance.

Thermosets & High-Pressure Laminates

Thermosets are cured irreversibly and do not melt — they offer superior dimensional stability, electrical insulation, and compressive strength compared to most thermoplastics. FedMat stocks eight thermoset grades: one glass-epoxy family and seven phenolic variants.

**G10 and FR4 (Glass Epoxy Laminate), FR4 = G10 + UL94 V-0 flame retardant. Dielectric strength 800 V/mil, no moisture absorption, dimensionally stable. PCB substrates, knife handles, tooling fixtures, and aerospace insulators.

Cotton Phenolic (NEMA CE/C) — Cotton fabric reinforcement. Self-lubricating, oil-impregnable. Bushings, gears, pump vanes, thrust washers.

Linen Phenolic (NEMA L/LE) — Finer weave than cotton, smoother machined surface, better electrical properties. Preferred for precision gears and electrical insulators requiring tighter tolerances.

Canvas Phenolic (NEMA C/CE) — Heaviest cotton weave. Higher impact resistance than cotton or linen grades. Heavy-duty industrial gears, pump impellers, and large bushings.

Paper Phenolic (NEMA XX / XXX / XXXP) — Paper-reinforced phenolic. XX (general), XXX (electrical), XXXP (post-formable), XXXPC (cold-punchable). Dielectric strength 600 V/mil. Lowest-cost phenolic for electrical insulators and punched parts.

Glass Phenolic (NEMA G3/G5/G9/G11) — Glass-fabric reinforced. Higher temperature than cotton or paper phenolics. G11 is the high-temp epoxy variant. Structural insulators, transformers, and arc-resistant parts.

G7 / Glass Silicone Phenolic — Glass cloth + silicone resin. Continuous use 425–485°F, arc resistance >180 sec, MIL-I-24768/17. Aerospace insulators and high-temperature coil forms.

G9 / Glass Melamine Phenolic — Glass cloth + melamine resin. Outstanding arc and track resistance (>180 sec, MIL-I-24768/2). Max use 350°F. Arc chutes, switchgear, and circuit breakers.