Plastic is material consisting of any of a wide range of synthetic or semi-synthetic organic compounds that

are malleable and so can be molded into solid objects.

Plasticity is the general property of all materials which can deform irreversibly without breaking but, in the class of
moldable polymers, this occurs to such a degree that their actual name derives from this specific ability.
Plastics are typically organic polymers of high molecular mass and often contain other substances. They are usually
synthetic, most commonly derived from petrochemicals, however, an array of variants are made from renewable
materials such as polylactic acid from corn or cellulosics from cotton linters.[1]
Due to their low cost, ease of manufacture, versatility, and imperviousness to water, plastics are used in a multitude
of products of different scale, including paper clips and spacecraft. They have prevailed over traditional materials,
such as wood, stone, horn and bone, leather, metal, glass, and ceramic, in some products previously left to natural
materials.
In developed economies, about a third of plastic is used in packaging and roughly the same in buildings in
applications such as piping, plumbing or vinyl siding.[2] Other uses include automobiles (up to 20% plastic[2]), furniture,
and toys.[2] In the developing world, the applications of plastic may differ—42% of India's consumption is used in
packaging.[2]
Plastics have many uses in the medical field as well, with the introduction of polymer implants and other medical
devices derived at least partially from plastic. The field of plastic surgery is not named for use of plastic materials, but
rather the meaning of the word plasticity, with regard to the reshaping of flesh.
The world's first fully synthetic plastic was bakelite, invented in New York in 1907, by Leo Baekeland[3] who coined the
term 'plastics'.[4] Many chemists have contributed to the materials science of plastics, including Nobel
laureate Hermann Staudinger who has been called "the father of polymer chemistry" and Herman Mark, known as
"the father of polymer physics".[5]
The success and dominance of plastics starting in the early 20th century led to environmental concerns regarding its
slow decomposition rate after being discarded as trash due to its composition of large molecules. Toward the end of
the century, one approach to this problem was met with wide efforts toward recycling.

The First Synthetic Plastic

The first synthetic polymer was invented in 1869 by John Wesley Hyatt, who was
inspired by a New York firm’s offer of $10,000 for anyone who could provide a
substitute for ivory. The growing popularity of billiards had put a strain on the supply
of natural ivory, obtained through the slaughter of wild elephants. By treating
cellulose, derived from cotton fiber, with camphor, Hyatt discovered a plastic that
could be crafted into a variety of shapes and made to imitate natural substances like
tortoiseshell, horn, linen, and ivory.

Thermoset
Thermoset Curing Process
Thermoset plastics contain polymers that cross-link together during the curing process to form an irreversible
chemical bond. The cross-linking process eliminates the risk of the product remelting when heat is applied,
making thermosets ideal for high-heat applications such as electronics and appliances.

Thermoset plastics significantly improve the material’s mechanical properties, providing enhances chemical
resistance, heat resistance and structural integrity. Thermoset plastics are often used for sealed products due
to their resistance to deformation.
Pros
 More resistant to high temperatures than thermoplastics
 Highly flexible design
 Thick to thin wall capabilities
 Excellent aesthetic appearance
 High levels of dimensional stability
 Cost-effective

Cons
 Cannot be recycled
 More difficult to surface finish
 Cannot be remolded or reshaped

Thermoplastics
Thermoplastics Curing Process
Thermoplastics pellets soften when heated and become more fluid as additional heat is applied. The curing
process is completely reversible as no chemical bonding takes place. This characteristic allows thermoplastics
to be remolded and recycled without negatively affecting the material’s physical properties.

There are multiple thermoplastic resins that offer various performance benefits, but most materials commonly
offer high strength, shrink-resistance and easy bendability. Depending on the resin, thermoplastics can serve
low-stress applications such as plastic bags or high-stress mechanical parts.

Pros
 Highly recyclable
 Aesthetically-superior finishes
 High-impact resistance
 Remolding/reshaping capabilities
 Chemical resistant
 Hard crystalline or rubbery surface options
 Eco-friendly manufacturing

Cons
 Generally more expensive than thermoset
 Can melt if heated
Grades and lots
1 – Polyethylene Terephthalate (PET or PETE or Polyester)

PET is also known as a wrinkle-free fiber. It’s different from the plastic bag that we
commonly see at the supermarket. PET is mostly used for food and drink packaging
purposes due to its strong ability to prevent oxygen from getting in and spoiling the product
inside. It also helps to keep the carbon dioxide in carbonated drinks from getting out.
Although PET is most likely to be picked up by recycling programs, this type of plastic
contains antimony trioxide—a matter that is considered as a carcinogen—capable of causing
cancer in a living tissue. The longer a liquid is left in a PET container the greater the
potential for the release of the antimony. Warm temperatures inside cars, garages, and
enclosed storage could also increase the release of the hazardous matter.
2 – High-Density Polyethylene (HDPE)
Quite special compared to the other types, HDPE has long virtually unbranched polymer
chains which makes them really dense and thus, stronger and thicker from PET. HDPE is
commonly used as the grocery bag, opaque milk, juice container, shampoo bottles, and
medicine bottle.
Not only recyclable, HDPE is relatively more stable than PET. It is considered as a safer
option for food and drinks use, although some studies have shown that it can leach
estrogen-mimicking additive chemicals that could disrupt human’s hormonal system when
exposed to ultraviolet light.
3 – Polyvinyl Chloride (PVC)

PVC is typically used in toys, blister wrap, cling wrap, detergent bottles, loose-leaf binders,
blood bags and medical tubing. PVC or vinyl used to be the second most widely used plastic
resin in the world (after polyethylene), before the manufacture and disposal process of PVC
has been declared as the cause of serious health risks and environmental pollution issues.
In the term of toxicity, PVC is considered as the most hazardous plastic. The use of it may
leach a variety of toxic chemicals such as bisphenol A (BPA), phthalates, lead, dioxins,
mercury, and cadmium. Several of the chemicals mentioned may cause cancer; it could also
cause allergic symptoms in children and disrupt the human’s hormonal system. PVS is also
rarely accepted by recycling programs. This is why PVC is better best to be avoided at all
cost.
4 – Low-Density Polyethylene (LDPE)
As said before, Polyethylenes are the most used family of plastics in the world. This type of
plastic has the simplest plastic polymer chemical structure, making it very easy and very
cheap to process. LDPE polymers have significant chain branching including long side chains
making it less dense and less crystalline (structurally ordered) and thus a generally thinner
more flexible form of polyethylene.
LDPE is mostly used for bags (grocery, dry cleaning, bread, frozen food bags, newspapers,
garbage), plastic wraps; coatings for paper milk cartons and hot & cold beverage cups;
some squeezable bottles (honey, mustard), food storage containers, container lids. Also
used for wire and cable covering.
Although some studies have shown that LDPE could also cause unhealthy hormonal effects
in humans, LDPE is considered as a safer plastic option for food and drink use.
Unfortunately, this type of plastic is quite difficult to be recycled.
5 – Polypropylene (PP)

Stiffer and more resistant to heat, PP is widely used for hot food containers. Its strength
quality is somewhere between LDPE and HDPE. Besides in thermal vests, and car parts, PP
is also included in the disposable diaper and sanitary pad liners.
Same as LDPE, PP is considered a safer plastic option for food and drink use. And although
it bears all those amazing qualities, PP isn’t quite recyclable and could also cause asthma
and hormone disruption in human.
6 – Polystyrene (PS)

Polystyrene is the Styrofoam we all commonly used for food containers, egg cartons,
disposable cups and bowls, packaging, and also bike helmet. When exposed with hot and
oily food, PS could leach styrene that is considered as brain and nervous system toxicant, it
could also affect genes, lungs, liver, and immune system. On top of all of those risks, PS
has a low recycling rate.
7 – Other
Number 7 is for all plastics other than those identified by number 1-6 and also plastics that
may be layered or mixed with other types of plastics, such as bioplastics. Polycarbonate
(PC) is the most common plastic in this category, isn’t used as much in recent years due to
it being associated with bisphenol A (BPA). PC is also known by various name: Lexan,
Makrolon, and Makroclear. Ironically, PC is typically used for baby bottles, sippy cups, water
bottles, water gallon, metal food can liner, ketchup container, and dental sealants. Due to
its toxicity, several countries have banned the use of PC for baby bottles and infant formula
packaging.
The BPA that contained inside PC have been linked to numerous health problems including
chromosome damage in female ovaries, decreased sperm production in males, early onset
of puberty, various behavioural changes, altered immune function, sex reversal in frogs,
impaired brain and neurological functions, cardiovascular system damage, adult-onset (Type
II) diabetes, obesity, resistance to chemotherapy, increased risk of breast cancer, prostate
cancer, infertility, and metabolic disorders.
PROPERTIES OF PLASTIC MATERIALS
Following are the general properties of plastics.

1. STRENGTH
The plastics are sufficiently strong and can be used for load bearing structural
members. The strength of plastics can further be increased by reinforcing them
with various fibrous materials.

Plastic as structural material has not gained much popularity because of the
following resins.

 High cost of construction

 High temperature susceptibility
 Poor stiffness
 Being subjected to creep under constant load

2. WEATHER RESISTANCE
The plastics, prepared from phenolic resins, are only good in resisting weather
effects. Certain plastics are seriously affected by ultraviolet light.

3. FIRE RESISTANCE
Plastics, being organic in nature, are combustible. But the resistance to fire
temperatue depends upon the plastic structure.

 Cellulose acetale plastics burn slowly.

 Polyvinyl chloride (PVC) plastics are non-inflammable.
 Phenol formaldehyde and urea formaldehyde plastics are used as fire
proofing materials.

4. DURABILITY
Plastics generally possess sufficient durability, provided they offer sufficient
surface hardness. Thermoplastic varieties are found to be attacked by termites
and rodents.
5. DIMENSIONAL STABILITY
Plastics easily maintain its shape and do not go under plastic deformations.

6. CHEMICAL RESISTANCE
Plastics offer great resistance to moisture, chemicals and solvents. Many plastics
are found to possess excellent corrosion resistance. Plastics are used to convey
chemicals.

7. THERMAL RESISTANCE
The plastics have low thermal conductivity and therefore foamed or expanded
varieties of plastics are used as thermal insulators.

8. WORKING CONDITIONS
All operations like drilling, sawing, punching, clamping etc are carried out easily
on plastics, just like wood.

9. MOISTURE RESISTANCE
This property depends upon variety of plastics used, for example, cellulose
plastics are considerably affected by the presence of moisture, whereas polyvinyl
chloride plastics offer high resistance to moisture.

10. DUCTILITY
Plastics, generally, have low ductility and hence plastic structural members may
fail without prior warning.
Processing Properties
MELT FLOW INDEX
The melt flow index (MFI) or melt flow rate (MFR) is a measure for the ease of flow of
melted plastics. It is often used in the plastic industry for quality control of
thermoplastics. The method is described in the standards ASTM D1238 and ISO 1133.
A small sample of about 5 grams is heated above its melting or softening point and
forced to flow through a capillary using a piston actuated by a specified weight, usually
2.16 kg or 5 kg. The weight of melt in grams flowing through the capillary in 10 minutes
is the melt flow index.
 MELT FLOW INDEXER

Melt flow indices are often listed on data sheets of thermoplastic materials. In general, a
higher MFI indicates a lower material viscosity, and when comparing polymers of the
same class, a lower melt flow rate corresponds to a higher molecular weight and/or less
branching.

The melt flow indexer is the most popular device in the plastic industry to determine
material viscosities and is often used to test batch-to-batch consistency. However, it is
also the least accurate method. To obtain more accurate and meaningful viscosity data,
a capillary or a cone and plate rheometer should be used. Some companies will also
perform in-mold rheology tests using actual manufacturing molds.

Shrinkage

Contraction of Plastics Molded Part

The shrinkage of plastics signifies the volume contraction of polymers during the
cooling step of the processing of polymers. This contraction is partly due to the
difference of density of polymers from the melt state and the cooled, rigid state.
Most of the plastic molded part shrinkage occurs in the mold while cooling. A
small amount of shrinkage occurs after ejection as the part continues to cool and
after that the part may continue to shrink very slightly until the temperature and
moisture content stabilize. In higher shrink materials such as acetal and nylon,
the post-mold shrinkage can be significant.

If the regions of the part shrink unequally (called as warpage) stresses are created
within the part which, depending on part stiffness, may cause the part to deform
or change shape and hence leading to cracks in parts during long term use.

The shrinkage of molded plastic parts can be as much as 20% by volume,

when measured at the processing temperature and the ambient temperature.

Engineering Uses of Plastic

Mechanical Units Under Stress. Cams, gears, couplings and such other mechanical components
are examples of these applications. Requirements of a plastic for such uses would include high
impact and high tensile strength, excellent stability and resistance to fatigue, along with the
ability to perform for long periods at high temperatures. Good environmental resistance is
sometimes required for these applications and the materials must be easily formed and
perform continuously to close tolerance. The plastics most frequently used for such
applications include the acetals, nylons, fabric-filled phenolics, and polycarbonates. The
principal competitive materials for these uses are brass, iron, and steel.

Low Friction Components. Wear surfaces, slides, bearings and guides are components requiring
low friction qualities. The most important requirement for these applications is, of course, a low
coefficient of friction. Also important are good dimensional stability, heat resistance, and good
abrasion resistance. The plastics most used for low friction applications include the
fluorocarbons, nylons, acetals, and even ultra-high molecular weight polyethylene. Competitive
non-plastic materials for these applications include the Babbitt metals, bronze, iron, and
graphite.

Chemical and Heat Resistant Equipment. Chemical and other processing equipment, certain
undcr-the-hood automotive parts and aerospace components are examples of these
applications. Obviously the most desired properties of plastics going to such uses would include
the excellent resistance to high temperatures and corrosive environments, along with good
strength and, in some instances, resistance to shock and vibration. Because of the unique
demand placed on such requirements, the highly stable plastics are used here, such as the
fluorocarbons, chlorinated polyether, and glass-reinforced epoxy. The expensive metals, such
as the stainless steels and titanium are the materials most competitive with plastics for these
applications.

Electrical Parts. Example applications here are connectors, relays and other electrical and
electronic parts. Good electrical resistance, of course, is an important required property. Other
required properties are good dimensional stability, good tensile strength, and impact
resistance. Candidates for these applications are mostly the thermosets, such as the alkyds,
aminoplastics, epoxies, and phenolics, but certain thermoplastics are also used here including
polycarbonate and polyphenylene oxide. Glass and ceramic would, of course, come to mind as
principal materials competitive with plastics for these electrical uses.

Containers, Ducts and Housings. Plastics going to these applications should have good strength
in all respects and good environmental resistance. They should be easily formed, with relatively
low cost being a prime factor. Plastics finding wide use here include ABS, polypropylene, glass-
polyester combinations, cellulose acetate butyrate, and some others. Competitive materials for
these applications include steel, aluminum, and die-cast metals.

Glazing — High Light Transmission Units. Applications here include lenses and protective
domes, in addition to glazing. Obviously, high light transmission and even transparency are
required properties for plastics going to these applications. Other desired properties of plastics
for these uses include good impact strength and frequently a high resistance to ultraviolet
radiation. Products mostly used here are, of course, acrylics which possess excellent ultraviolet
resistance, and polycarbonate which has unusually high impact resistance. Other plastics used
here include polystyrene, cellulose acetate, and rigid vinyl. Glass, of course, is the principal
competitive material.

Miscellaneous Applications. There are many such uses, some of which will be questioned as
engineering. Some of these applications include building construction, luggage, safety-helmets,
seating, kitchen utensils, rope and strapping, shoe parts, rollers, furniture, and even dentures.
This list can go on almost indefinitely and the plastics used, reflecting desired properties, will
vary widely.

It is probably safe to say that most engineering plastics are formed by molding but many other
forming techniques are used, including machining, sintering, stamping, and casting. Other
forming techniques are, of course, used also.
https://apt-mold.com/wp-content/uploads/2017/09/DIN-16901.pdf (DIN standard for tolerance of
plastic mould)

https://ed.iitm.ac.in/~shankar_sj/Courses/ED5312/Materials_for_Automobiles17.pdf( tables and shit)