MANUFACTURING
The use of Thermosetting and Thermoplastic Polymers in electronic applications
Patrick Faulkner, lead engineer at precision engineering component distributor Accu, discusses thermosetting and thermoplastic polymers and what makes them suitable for use in electronic applications.
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n electronics, choice of material plays a crucial role in determining performance, durability and reliability. Having an understanding of the chemical structures, performance characteristics and environmental considerations between thermosetting and thermoplastic polymers means that engineers can make informed decisions when selecting the most appropriate polymer for their electronic applications.
Chemical Structure and Bonding There are important differences between thermosetting and thermoplastic polymers to consider. The main difference between them is their performance and reaction to the application of heat, this is
10 APRIL 2025 | ELECTRONICS FOR ENGINEERS
due to chemical structure and bonding mechanisms. This determines their behaviour under various conditions and their suitability for different electronic applications.
Thermosetting Polymers Overview Thermosetting polymers, also known as thermosets, are characterised by their irreversible chemical reactions during the curing process. When exposed to heat or form strong, three-dimensional cross-linked structures. This cross-linking occurs between polymer chains, creating a rigid network that cannot be melted or reshaped once formed. It is the cross-linking which gives thermosets their thermal stability, chemical
resistance and mechanical strength. Common examples of thermosetting polymers include epoxy resins, phenolic resins and polyurethanes. These materials are widely used in electronic components that require high-temperature resistance and dimensional stability.
Thermoplastic Polymers Overview In contrast, thermoplastic polymers have a linear or branched molecular structure without cross-linking. These polymers are held together by weak intermolecular forces, such as van der Waals forces or hydrogen bonding. As a result, thermoplastics can be repeatedly melted, reshaped and chemical structure.
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