Not All Plastics are Polluters: The Sustainable Advantage of Thermoset Polymers

Pollution from plastic consumer packaging has become a serious environmental concern around the world. However, some industrial plastics are actually sustainable options for making parts on durable goods. Thermoset plastics are highly strong and long lasting, so they’re less likely to fail and end up in a landfill. These performance characteristics make thermoset a smarter and more environmentally responsible solution for making parts in many sectors such as cookware, electrical, marine and outdoor equipment.

Today’s throw-away culture has driven engineered obsolescence for most consumer plastics, resulting in tons of single-use plastic waste. Common offenders are polyethylene terephthalate (PET) and high-density polyethylene (HDPE) which are commonly used in consumer packaging. While they’re intended to be recycled, a large percentage of plastics end up in landfills.

However, not all plastics are the same. In fact, thermoset plastics used in many industrial applications are chosen purposefully for their longevity and durability, making them an environmentally sustainable solution. 

Made to last

Thermoset plastics are made of polymer resins that are cured through a heat and chemical cross-linking process. This curing process transforms the resin into its final form, which cannot be melted or re-shaped. Phenolic, polyester and epoxy are three different resin systems used to make thermoset compounds. These materials are reinforced with fibers such as carbon and glass, resulting in heat-resistance and surface hardness that give parts a reliable, extended service life. Thermoset materials are generally stronger than thermoplastic materials (such as PET and HDPE) and are better suited for high-temperature and high-strength applications than many other types of plastics. Their dimensional stability is ideal for applications where other types of plastics may tend to “creep” under high heat conditions. 

In the home, thermoset plastics are found in handles on pots, pans and oven doors. Many exterior and interior parts on lawn mowers and ATVs are made of thermoset materials. Due to their dielectric strength, it’s common to see thermoset parts used in electric/power applications such as switchgear, battery housings and utility insulators. In all of these applications, the thermoset parts are engineered to endure harsh conditions for the long term. Learn about more thermoset applications here.

More sustainable than metal

Thermoset materials are an excellent metal replacement in some applications. In addition to longer life than thermoplastic resin, thermoset composites take less energy to manufacture and the thermoset molding process uses less energy to produce parts than metal fabrication.  Plus, many thermoset composites, on average, weight nearly 400% less than steel and 150% less than aluminum without sacrificing performance if designed correctly. Lighter weight parts can help reduce fuel consumption in industries such as automotive and aerospace, which often have aggressive sustainability initiatives

Manufacturing applications 

Here are a few real examples of manufacturers that chose to use thermoset materials for high durability and long life:

• Strongwell updated its industrial railing systems with thermoset resin connectors instead of thermoplastic to better stand up to corrosive environments like those found in industrial, chemical and wastewater treatment plants as well as commercial structures with urban and salt air corrosion. 

• Eaton redesigned their aluminum cast outdoor electrical enclosures to thermoset to reduce weight, which are difficult to access for change-outs. 

• To implement a new missile defense radar for the U.S. government,  a military defense contractor chose thermoset materials for the insulators on the new pole bases because thermoset insulators installed on radar arrays 30 years ago were still in excellent condition. 

• Another manufacturer changed the material of the brush holder assembly on its portable generator from thermoplastic to thermoset plastic to prevent premature failure and reduce warranty claims. 

As more organizations expand their sustainability programs, thermoset materials can help achieve performance and price goals while giving parts a long life so they aren’t contributing to landfill waste.

Contact Ci-Dell to help you achieve your business goals with thermoset parts.