High-performance components for general industrial applications vary in both complexity and performance requirements. The design of critical parts such as seals, valve seats, piston rings, bushings, fluid handling components, and high-temperature fittings must consider not only precise dimensions and fit but also material selection. In demanding industrial application the material selection process should include factors such as wear resistance, chemical compatibility, thermal stability, and mechanical strength as they are crucial in ensuring performance and durability. The right combination of design and material choice enhances reliability, extends service life, and reduces maintenance requirements.

Considerations in Material Selection for Industrial Applications

The material selection process for industrial applications requires a comprehensive understanding of operational conditions. Components must withstand mechanical loads, resist environmental degradation, and maintain functionality under extreme temperatures or corrosive conditions. Material cost, as well as the specific environmental and physical requirements of the  application are a guide during the material selection process. Some of the common material properties include the following:

  • Mechanical Strength and Wear Resistance – Industrial machinery operates under high loads, requiring materials that can endure continuous stress without deformation or failure. Materials with excellent chemical and wear resistance, such as TECAPEEK (polyetheretherketone) and TECATRON PPS (polyphenylenesulfide), are often filled with solid lubricants such as PTFE, graphite and carbon fiber for use as bushings, bearings, and gears. These materials provide excellent performance as self-lubricating bearings and wear components. They require little or no external lubrication and can survive in the most austere environments.
  • Chemical Resistance – Many industrial environments expose components to aggressive chemicals, solvents, and corrosive fluids. Choosing materials with high chemical resistance ensures longevity and performance stability. TECAPEEK (polyetheretherketone), TECATRON PPS (polyphenylenesulfide) and TECAFLON PVDF (polyvinylidene fluoride) are widely used in fluid handling and sealing applications because they resist harsh chemicals while maintaining their structural integrity.
  • Thermal Stability – All materials are affected by changes in temperature. Extreme temperatures can not only compromise material properties, but they can also significantly change the dimensions of a component. Every material has a coefficient of thermal expansion, some of which can be many times greater than steel. The result of which can lead to the reduction of clearances and and/or catastrophic failure. Industrial applications often require materials capable of maintaining performance across a broad temperature range. High-temperature materials such as PI (Polyimide), PAI (polyamide-imide) and PPSU (polyphenylsulfone) are ideal for applications where thermal resistance is critical, such as high-temperature fittings and insulating components.
  • Friction and Lubrication – Reducing friction in moving parts improves efficiency and extends component life. Several materials can be modified with solid lubricants such as PTFE, graphite, molybdenum difulfide and carbon fiber. These fillers provide self-lubrication and dimensional stability in fluxuating temperatures. Materials such as Delrin, Nylon, TECATRON PPS and TECAPEEK are frequently filled with these solid lubricants in various combinations and concentrations to meet the needs of certain and specific environments. This makes them particularly valuable in bearing and wear applications in the pump, rail and fluid handling industries.
  • Electrical Insulation – For applications involving electrical and electronic components, Ensinger materials provide a wide range of electrical properties. From fully insulating to electrostacically dissipative to fully conductive. High-performance polymers such as TECAPEI (polyetherimide) and TECATRON PPS and TECAPEEK offer excellent dielectric properties, each of which can be custom compounded to suit applications in semiconductor and sensor mafufacturing industries.

Application Evaluation for Material Selection

However, each application must be evaluated to thoroughly understand its physical, chemical and temperature requirements before selecting a material. Engineers determine the appropriate plastic material during a project’s design and development phase, ensuring that the selected material meets all requirements. This process typically involves several steps and considerations:

  • Defining Application Requirements – Engineers assess mechanical loads and stress, type of stress, duration of stress or load, whether it must retain shape under load or stress, thermal exposure, chemical interactions, compatibility, abrasion and wear requirements, and environmental conditions to outline the necessary material properties.
  • Material Screening and Testing – Based on the defined requirements, potential materials are evaluated for their suitability using manufacturer data, industry standards, and simulation tools.
  • Prototype Development and Testing – Engineers create prototypes and subject them to real-world testing to ensure the material performs as expected under operational conditions.
  • Cost and Manufacturability Analysis – Factors such as processing methods (e.g., injection molding, CNC machining), availability, and cost-efficiency may influence the final material selection.
  • Regulatory and Compliance Considerations – For applications in industries such as food processing, medical devices, or aerospace, compliance with industry standards and regulations (e.g., FDA, ISO, UL) is necessary.

Common High-Performance Polymers in Industrial Applications

The industrial sector relies on high-performance polymers for demanding engineering and manufacturing applications. These advanced materials offer exceptional properties for various uses. Below are a few commonly used high-performance plastics and the characteristics that make them attractive for industrial components. Each of them are available in semi-finished stock shapes, CNC Precision machined components or injection molded parts:

  • TECAPEEK (Polyether Ether Ketone) – TECAPEEK is one of the most versatile high-performance polymers used in industrial applications. It offers exceptional mechanical properties, high-temperature resistance, and chemical stability. TECAPEEK is commonly used in gears, bushings, and pump components where durability and resistance to extreme conditions are required.
  • TECAPAI (Torlon)(Polyamide-imide) – TECAPAI (Torlon) is a high performance material that has a continuous service temperature of 480 °F. It is available in several filled grade for use as bearing and wear components such as bearings and seals. PAI excels in chemically aggressive seal and valve seat applications.
  • TECATRON PPS (Polyphenylene Sulfide) – TECATRON PPS provides high mechanical strength and excellent chemical resistance to 200°C (392°F). It is often used in structural components, high-temperature fittings, and electronic housings. It is often used as a lower-cost alternative to TECAPEEK at lower temperatures.
  • TECAPEI (Polyetherimide) – TECAPEI provides high strength, electrical insulation, and resistance to heat and chemicals, making it a preferred choice for electrical components and industrial housings.

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We understand that finding the right material for your specific industrial needs can be challenging. Our team of experts is dedicated to working closely with you to identify and develop the best solutions. From initial consultation through to final implementation, we are here to support you every step of the way. Contact us to learn more about our material offerings and how we can support your projects with quality, innovation, and service.