Industrial plastic components are transforming industries by elegantly supplanting traditional metal parts. Their exceptional material properties introduce a myriad of enticing benefits:
1. Lightweight
Plastics, with their considerably reduced density in comparison to metals, emerge as an optimal choice for applications where weight is critical. For example, PP has a density of 0.9g/cm³, compared to aluminum's 2.7g/cm³. This makes plastics an impeccable fit for automotive and aerospace sectors, where decreasing energy consumption is paramount.
2. Corrosion resistance
With formidable stability against aggressive chemicals like acids, alkalis, and salts, materials such as PTFE, capable of enduring concentrated sulfuric acid, are ideal for chemical apparatus and sewage treatment facilities, offering lifespans 3-5 times longer than those of metals.
3. Insulation and safety
Featuring a volume resistivity surpassing 10^16Ω·cm, materials like PE are superb selections for high-voltage cables and electronic housings, ensuring safety by mitigating leakage hazards.
4. Design flexibility
Plastic injection molding facilitates the crafting of complex geometric designs, such as thin-walled and irregular formations, reducing the need for assembly. Nylon gears, for example, can be molded directly into precise tooth configurations, negating post-processing requirements.
5. Cost effectiveness
The cost-effectiveness of raw materials, along with low energy requirements for processes such as injection molding, which uses merely 30% of the energy required for casting, renders plastics ideal for economical mass production.
6. Shock absorption and noise reduction
Plastics exhibit superior damping abilities compared to metals. For instance, POM gearboxes generate noise levels 15-20 decibels lower than their metal counterparts.
7. Wear resistance (specific material)
UHMWPE exhibits wear resistance that is eight-fold greater than carbon steel, with conveyor rails constructed from this material enduring up to a remarkable 10 years.
Typical application scenarios
Metal replacement: Employing PA66+GF30% for automobile intake manifolds reduces weight by 40% and cost by 25%, exemplifying the transformative potential of plastics.
Harsh environments: Utilizing PVDF for chemical pump valve linings provides outstanding corrosion resistance, prolonging lifespan to up to 8 years.
Precision limitation: For applications demanding extraordinarily high precision (<0.01mm tolerance), metal remains the material of choice.
Material selection suggestions
High temperature and high pressure: Choose PEEK>PPS>PA66 for optimal results.
Wear resistance: Favor UHMWPE>PTFE>Nylon for enduring performance.
Cost priority: PP>HDPE>PVC offers the most advantageous financial option.
By meticulously selecting materials (including modifying composites) and refining designs (such as incorporating reinforcement structures), any performance limitations of plastics can be adeptly mitigated.
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