Polysulfone Specifications — Sheet & Rod Sizes
Polysulfone stock shapes — sheet and rod in Udel PSU and Radel PPSU — are produced to established dimensional standards covering thickness, diameter, length, and allowable tolerances. This page documents available sizes for ordering, applicable ASTM material standards, and the dimensional considerations relevant when machining polysulfone to finished dimensions. Stock shapes are natural amber in both grades; no alternate colors are standard.
At a glance:
- Sheet: 12"×24" through 24"×48" standard panels, thicknesses 1/8" through 4"
- Rod: 1/4" through 4" diameter, standard 4-foot and 6-foot lengths
- Material standard: ASTM D6098 (polysulfone shapes), ASTM D6107 (polyphenylsulfone shapes)
- Thickness tolerance on sheet: ±10% of nominal (stock); tighter on request with machined finish
- Diameter tolerance on rod: −0/+0.030" typical on stock extruded rod
- Color: natural transparent amber — no standard opaque colors
- Certification: material certifications available upon request (lot trace, compliance to ASTM)
Sheet Specifications
Standard Sizes
Polysulfone sheet is produced by compression molding or extrusion, resulting in flat panels with consistent cross-section properties. Standard stock panel sizes are listed below. Custom-cut sizes are available from full panels.
| Nominal Thickness | Panel Size Options | Typical Weight (24"×48" panel) |
|---|---|---|
| 1/8" (0.125") | 12"×24", 24"×48" | 4.7 lb |
| 3/16" (0.188") | 12"×24", 24"×48" | 7.0 lb |
| 1/4" (0.250") | 12"×24", 24"×48" | 9.4 lb |
| 3/8" (0.375") | 12"×24", 24"×48" | 14.1 lb |
| 1/2" (0.500") | 12"×24", 24"×48" | 18.8 lb |
| 3/4" (0.750") | 12"×24", 24"×48" | 28.2 lb |
| 1" (1.000") | 12"×24", 24"×48" | 37.5 lb |
| 1-1/2" (1.500") | 12"×24", 24"×48" | 56.3 lb |
| 2" (2.000") | 12"×24", 24"×48" | 75.0 lb |
| 3" (3.000") | 12"×24" | ~56.3 lb per 12"×24" |
| 4" (4.000") | 12"×24" | ~75.0 lb per 12"×24" |
Weights calculated at PSU density 1.24 g/cc (0.0448 lb/in³). PPSU sheet at 1.29 g/cc is approximately 4% heavier per panel.
Sheet Dimensional Tolerances
Thickness tolerance of ±10% on stock sheet is standard for compression-molded plastic sheet across most materials. If your application requires tighter thickness control — for example, gasket stock or precision laminated assemblies — order oversized and machine to final thickness after stress-relief annealing.
Sheet Surface Condition
Stock polysulfone sheet is supplied with a machined or polished surface on both faces. The amber transparency allows inspection of internal bubbles or inclusions — compression-molded sheet of quality grades should be substantially free of voids visible to the naked eye. Minor surface scratches from handling are typical and do not affect mechanical properties.
Rod Specifications
Standard Diameters and Lengths
Polysulfone rod is extruded from Udel PSU or Radel PPSU resin into round rod. Standard lengths are 4 feet and 6 feet; some sizes are available in longer lengths by special order.
| Nominal Diameter | Tolerance (Standard) | Standard Lengths |
|---|---|---|
| 1/4" (0.250") | −0/+0.030" | 4 ft, 6 ft |
| 3/8" (0.375") | −0/+0.030" | 4 ft, 6 ft |
| 1/2" (0.500") | −0/+0.030" | 4 ft, 6 ft |
| 3/4" (0.750") | −0/+0.030" | 4 ft, 6 ft |
| 1" (1.000") | −0/+0.030" | 4 ft, 6 ft |
| 1-1/4" (1.250") | −0/+0.040" | 4 ft, 6 ft |
| 1-1/2" (1.500") | −0/+0.040" | 4 ft, 6 ft |
| 2" (2.000") | −0/+0.050" | 4 ft, 6 ft |
| 2-1/2" (2.500") | −0/+0.060" | 4 ft |
| 3" (3.000") | −0/+0.060" | 4 ft |
| 3-1/2" (3.500") | −0/+0.075" | 4 ft |
| 4" (4.000") | −0/+0.075" | 4 ft |
Rod Surface Condition
Extruded polysulfone rod has a smooth, machine-ready surface. No post-processing is required before turning. The surface is amber-transparent; inspect for surface voids or extrusion defects before beginning a machining operation. Small lot quantities should receive a visual inspection before committing to a finish machining operation.
ASTM Material Standards
Polysulfone shapes are defined under two ASTM standards:
ASTM D6098 — Standard Specification for Polysulfone Plastic Shapes
ASTM D6098 covers extruded and compression-molded sheet, rod, and tube made from polysulfone (PSU) resin. The standard defines:
- Cell classification for base resin properties (tensile strength, flexural modulus, heat deflection temperature)
- Dimensional tolerances by product form and nominal dimension class
- Test methods for property verification
ASTM D6107 — Standard Specification for Polyphenylsulfone Plastic Shapes
ASTM D6107 is the equivalent standard for PPSU shapes. It follows the same dimensional structure as D6098 but references polyphenylsulfone cell classification values consistent with Radel PPSU resin properties.
When ordering for regulated applications (medical device documentation, food equipment qualification), request material certifications referencing these ASTM standards and the lot number traceable to a specific production run.
Color and Transparency
Natural Amber
Both PSU and PPSU stock shapes are supplied in natural amber only. The amber color is an inherent property of the aromatic sulfone chemistry and cannot be changed without compounding with pigments — which is only done for injection-molded parts, not stock shapes.
The amber transparency allows visual inspection of fluid levels or contents through polysulfone walls. Transparency decreases with increasing section thickness — thin walls (≤1/8") are substantially transparent; 1"-thick rod stock is translucent but not clearly transparent.
PPSU amber is slightly darker and more brownish than PSU amber. The difference is visible side-by-side but not immediately obvious without comparison.
Ordering and Certification
Certifications Available
- Material certificate of conformance (C of C) to ASTM D6098 or D6107
- FDA 21 CFR 177.1655 compliance letter
- USP Class VI biocompatibility statement
- NSF 51 compliance documentation (Solvay Udel/Radel grades)
- Lot-traceable heat/lot number on documentation
Cut-to-Size Availability
Standard full panels (12"×24" and 24"×48") and rod cut to specific lengths are available. Saw-cut tolerances for cut-to-length service are typically ±1/8". For precision blanks requiring tighter tolerances, specify a machining allowance and plan to finish-cut at your facility after annealing.
For machining guidelines that affect dimensional outcomes, see the polysulfone machining guide. For compliance documentation context, see FDA and food-grade specifications. For material selection between PSU and competing materials, the polycarbonate vs. polysulfone comparison covers size-relevant considerations alongside property differences.
Order polysulfone sheet and rod — specify size, grade, and certification needs
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