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When to Use Thermoset vs. Thermoplastic Materials

In modern manufacturing, non-metallic polymer materials are becoming a common choice over metals for many applications. Not only are they lighter and more durable without sacrificing strength, they also resist corrosion and are often more cost-effective.

To truly unlock those advantages, it’s important to understand the differences between the two primary types of polymers: thermosets and thermoplastics. Each offers unique performance traits and may be more or less suitable for different applications.

Keep reading to learn the difference between these types of materials, examples of both, and tips for determining which is best for a given application.

What Is a Thermoset?

Thermosets are polymers that experience a permanent chemical change when cured. Once set, they can’t be melted and reshaped again. This gives them good dimensional stability and superior resistance to heat, chemicals, and mechanical stress.

Thermosets are good choices for applications where heat resistance and structural integrity are top priorities. They frequently outperform traditional metals, including high-stress environments where chemical exposure, temperature fluctuation, and vibration would cause premature component wear.

Examples of Thermoset Materials

Some common thermoset materials include:

• Phenolic (Ryertex^®): Ryertex is widely used in power generation and heavy equipment because it’s strong, rigid, and provides excellent electrical insulation.
• Epoxy and Polyester Composites: These composites offer dimensional stability and high fatigue resistance even under extreme load and temperature conditions.
• Melamine and Silicone Resins: They provide exceptional flame resistance and mechanical durability for specialized environments.

WS Hampshire uses Ryertex thermoset laminates for applications including power generation, where heat and vibration dramatically shorten the lifespan of metal components. The result is improved reliability and far fewer maintenance cycles.

What Is a Thermoplastic?

Unlike thermoset materials, thermoplastics can be softened by heat and reshaped numerous times without changing their chemical composition. This means they are recyclable and easier to machine than thermosets.

They are less resilient under high-heat or high-stress conditions; however, thermoplastics excel when made into wear parts in dynamic, wear-intensive systems. They are lighter than metals, minimize friction, and in contact motion systems, they commonly outperform metallic parts.

Examples of Thermoplastic Materials

• Nylon and UHMW (Ultra-High Molecular Weight Polyethylene): These are exceptional for bearings, bushings, and wear pads thanks to their self-lubricating properties.
• Acetal (POM): These materials are chosen for their low coefficient of friction, high stiffness, and excellent dimensional stability, making them ideal for gears and precision parts.
• PEEK (Polyetheretherketone): It excels in demanding applications due to its mechanical strength, temperature resistance, and chemical inertness.

Thermoplastics are widely used in WS Hampshire’s wear pad products. These nonmetallic pads have an extended service life, are not prone to corrosion, and protect structural supports, bridge bearings, and machinery from direct metal-on-metal contact.

How to Choose Between Thermoset vs. Thermoplastic Materials for Your Application

When choosing between thermoset and thermoplastic composites for an application, start by defining the primary operating environment and performance needs. Key considerations include:

• Will the part be exposed to high temperatures or constant loading?
  If so, thermosets are a better choice because of their stability and heat resistance.
• Does the part require flexibility or impact resistance? Will it be subject to repeated motion?
  Here, a thermoplastic would be best due to their pliability and relative softness compared to thermosets. Their low friction properties are ideal for moving parts in assemblies.
• Is corrosion a factor?
  Both thermosets and thermoplastics resist corrosion far better than most metals; however, the specific chemical exposure(s) of the application will determine which material is best.
• Do weight or wear resistance matter?
  Thermoplastics, UHMW and nylon in particular, offer dynamic wear resistance. They’re also significantly lighter than their metal counterparts.

Depending on the formulation and part design, nonmetallic materials can handle the same or even greater loads than metals. Our material experts at WS Hampshire can help you match the laminates and polymers to your application’s specific load, temperature, and wear profile.

Case Study: Long-Term Value in a Steel Mill Transformation

In one of our customer success stories, a steel mill used Ryertex nonmetallic materials in place of metal components. The old steel parts they once relied on required frequent maintenance and sustained damage from corrosion and surface scoring.

When they switched to Ryertex laminates and wear pads, the results were:

While the project started as a small retrofit job, it soon evolved into a full-scale transformation of the mill’s key mechanical systems. Its metal components were replaced with high-performance nonmetallic alternatives, resulting in many operational benefits.

Contact WS Hampshire for Expert Guidance

WS Hampshire specializes in custom fabrication of parts and components made from non-metallic materials. Our capabilities include CNC machining, punching, stamping, rotary die, vacuum forming, and assembly. We serve industries ranging from steel and aluminum rolling to mining to food processing and beyond, producing OEM-quality parts as well as small-volume custom components.

Contact us to discuss your application and to explore the thermoset and thermoplastic materials we offer.