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Plastics“I just want to say one word to you... just one word...
-the graduate
”
What are Polymers?
greek for many parts
long chains of repeating molecules (monomers)
natural polymers: proteins, starch, cellulose
synthetic polymers...
synthetically polymerized material... typically from hydrocarbons
from crude
6-10 percent of U.S. oil consumption - approximately 2 million barrels a day *
What is Plastic?
* lawrence livermore, 2004; metabolix 2007
green plastic oil can
Thermoplastics vs Thermosets
THERMO (heat) PLASTIC (deform)
THERMO (heat) SET (permanent)
ThermosetsPermanent, Chemical Reaction! Polymer Chains are cross-linked.
Usually two-part exothermic, or heat treated
Used in for high temp, high tolerance, or joining
not recyclable.
melamine
phenolics
vulcanized rubber
Acrylonitrile-Butadiene-Styrene (ABS)
PolyVinyl Chloride (PVC)
PolyPropylene (PP)
PolyEthylene (PE)
PolyStyrene (PS)
PolyMethylMethArylate (Acrylic)
PolyCarbonate (PC)
PolyEsters (PET, PETE)
PolyAmide (Nylon, PA)
Thermoplasticsmost common with toys
easy to (re)shape with different processes. chains relax
mostly recyclable
9 common thermoplastics
Plastic Shaping Processes
Compression Molding (thermosets)
Injection Molding
Thermoforming
Blow Molding
Rotational Molding
pdes 3706 designing for manufacture (fall)
Compression Molding
for complex parts with various thickness
thermosets
Injection Moldingfor thin constant thickness parts
gate, parting lines, ejector pins
mass production, molds are expensive
Thermoforming
glass transition, relaxing the chains
for thin sheets, simple one sided forms
Blow Molding
for open thin walled hollow parts
milk jugs, most bottles
Rotational Molding
for simple closed hollow shapes
good for inexpensive large parts
Crazing
network of small voids or cracks
strain whitening
Acrylonitrile-Butadiene-Styrene (ABS)
PolyVinyl Chloride (PVC)
PolyPropylene (PP)
PolyEthylene (PE)
PolyStyrene (PS)
PolyMethylMethArylate (Acrylic)
PolyCarbonate (PC)
PolyEsters (PET, PETE)
PolyAmide (Nylon, PA)
Thermoplastics
ABS PVC PP PE
popular toy plastics
PS PETPMMA PC
popular clear plastics
Physical Properties: feel, look, smell, density, stiffness, opacity, surface finish
Manufacturing Properties: What are the processes used with this plastic? thickness, detail, size?
Design Considerations: Which types of products use this plastic? What is the cost of these products?
Thermoplastics Game
ABS PVC PP PE
popular toy plastics
PS PETPMMA PC
popular clear plastics
ABSHard with high impact resistance
Takes color well with excellent surface finish
Consumer product cases
Most expensive out of PVC, PP, PE
PolyVinylChloride (PVC)cheap, heavy, rigid, durable but not tough without plasticizers
vinyl designer toys - not constant thickness
outdoor/water products
characteristic smell
environment concerns
PolyEthylene (PE)most common plastic
HDPE, LDPE
cheap, very flexible, easy to (blow) mold, less dense than water
waxy feel, milky, crazes
highly resistant to food, water, salt, chemicals
PolyPropylene (PP)VERY similar to PE but...
a bit more rigid
doesn’t fatigue: hinges, snaps
shinier surface with better color acceptance
harder to scratch and craze
Compare ABS, PVC, PP, PE
ABS PVC PP PEHard
ColorfulStrong
Durable/GummyFlexible*
Unique shapes
No FatigueTough
Shiny Surface
FlexibleFood/Chemical Safe
Waxy
Stiff Flexible
High $ Low $
Nicest Finish Worst Finish
Polystyrene (PS)
clear, hard, cheap, brittle, tinny sound
typically foamed to Styrofoam
good for lightweight insulation
if it cracks or crazes easily
PolyMethylMethAcrylatePMMA, Acrylic, Plexiglass
transparent like glass, hard, brittle, but stronger than PS
great for laser cutting
can weld with superglue
PMMA particles suspended in water
Polycarbonate (PC)
the “engineering” plastic
expensive, extremely tough and rigid...
and clear
Polyesters (PET, PETE)cheap, transparent, easy to blow mold
food products, barrier to moisture
tough, able to withstand high pressures
easy to recycle, require less energy than glass bottles
Compare PS, PMMA, PC, PET
PETAcrylic PCPStin sound
brittlelight weight
glass likeless brittle
toughhard
water prooftough
blow mold
Brittle StrongLow $ High $
Quiz1. Identify the plastic that makes up the majority of each toy piece.
2. What makes you think it is that plastic? / Why was that plastic used?
Plastic Recycling
* 2001 Environment Agency report
not everything gets recycled (even if it’s recyclable)
collecting “air”, sorting, shredding, cleaning processing
80% is sent to landfill 8% is incinerated 7% is recycled *
Paper vs. Plastic2 plastic bags use 13% less energy to make than one paper bag
and produce 72% less pollutants than one paper bag
but do not degrade and come from a non renewable resource
* institute for lifecycle environmental assessment
Logistics
ONLY 3 Weeks left!
PLAYsentations are Wednesday May 3rd, 6pm, Coffman Theatre
Rehearsal is Monday May 1st, 2-930 pm, Coffman Theatre (30 min slots)
Presentation Consultations: April 24 and 26 in Rapson 37 (Bring 3 ideas) (Kate Maple and Chris Schlichting)
Keynote
PLAYsentations guidelines Monday lecture
Questions