MANUFACTURING
This characteristic allows thermoplastics to be easily processed and recycled, making them suitable for various electronic applications. Examples of thermoplastic polymers include polyethylene, polypropylene and polyvinyl chloride (PVC). These materials are often used in electronic housings, cable insulation and 3D-printed prototypes.
Manufacturing
The manufacturing processes for thermosetting and thermoplastic polymers performance characteristics, which various electronic applications. The production of thermosetting plastics involves the following two-stage process. Firstly, a low molecular weight
prepolymer is created through a controlled polymerisation reaction. This prepolymer is typically in a liquid or semi-solid state. Secondly, the prepolymer is subjected to heat, pressure or catalysts to initiate the cross-linking reaction. This process, known as curing, transforms the material into its
Common manufacturing techniques for thermosetting polymers include: • Compression moulding • Transfer moulding • Injection moulding • Resin transfer moulding (RTM) These methods allow for the production of complex shapes and structures with excellent dimensional stability and surface
Thermoplastic polymers on the other hand are typically produced through
a single-stage process involving the polymerisation of monomers. Once the polymer is formed, it can be processed into various shapes and forms using different techniques such as: • Injection moulding • Extrusion (including 3D printing) • Thermoforming • Blow moulding
The ability to melt and reshape thermoplastics allows for more versatile manufacturing processes and easier recycling compared to thermosets.
Performance
Thermosetting polymers stand out for their ability to handle high temperatures without losing structural integrity. Instead of melting, they typically char or burn when
exposed to extreme heat, making them an excellent choice for electronic devices or any applications that may encounter structure gives them impressive chemical resistance and ensures minimal expansion or contraction, which helps maintain consistent dimensions. This same structure also boosts their mechanical strength and many thermosets offer top-notch electrical insulation.
Despite these advantages, thermosetting polymers do come with some downsides. They can be brittle, which makes them more likely to crack if they experience sudden stress or impact. The curing process can take time and uncured resins usually have a short shelf life, demanding careful storage. Additionally, recycling fully cured thermosets
On the other hand, thermoplastics bring be melted and reshaped multiple times, they are relatively straightforward to recycle. faster production cycles and you can even weld different thermoplastic components together. Generally speaking, thermoplastics are more budget-friendly to produce and process. However, they do not resist heat as well as thermosets and can show more temperatures shift. Under constant stress, thermoplastics may also experience creep or deformation, which can limit their use in certain engineering applications.
Applications in electronics for Thermosets
Thermosetting and thermoplastic polymers each possess distinct advantages that
APRIL 2025 | ELECTRONICS FOR ENGINEERS 11
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