Working from the requirements of the application, the proper Engineering Thermoplastic is selected, and the profile designed, so as to simplify, improve and increase the value of your design. Snap together assembly and snap apart disassembly, living hinges, multi-lumen tubing, elastomeric and optical properties are all used in designing with Engineering Thermoplastics. Secondary operations such as drilling, tapping, notching, adhesive bonding and welding are all incorporated into Engineering Thermoplastics extrusion products. There is an almost unlimited color selection with most Engineering Thermoplastics. All standard plastics decorating methods are available. An extruded Engineering Thermoplastic does not ordinarily require any further processing such as de-scaling, passivating, annealing or painting. Extrusion tooling costs are modest. However, complicated tubes, through holes, tight tolerances, thick/thin walls and other violations of the design rules outlined later at this website do increase tooling costs.

Extruded shapes of Engineering Thermoplastics or their compound are used for bearings, sliding surfaces, bushings, anywhere there is relative motion between contact parts. Usually, no additional lubrication is required. Resins that are often used include Fluoropolymers, Nylons, Olifins and Polyketones. To enhance properties, these and other resins are compounded with PTFE, Aramid fiber and Molybedenum Disulfide.
The selection of the material to use is based on the pressure and velocity between the surfaces, the operating environment, and the nature of the mating surface.
The use of an anti-friction extrusion is often an opportunity to combine parts. These materials generally require strict adherence to the rule of even wall thickness.

Parts made from Engineering Thermoplastics are often used in harsh environments: temperatures up to 300°C (575°F) and down to -60°C (-76°F); exposure to radiation from UV, gamma rays, X-rays and microwave; a full range of chemicals, organic and mineral including solvents, water and sea water.
Materials for extreme temperature use include Fluoropolymers, Polyketone, Polysulfones, Nylon 11 and 12, as well as their compounds. Depending on the circumstances, many resins, alloys and compounds will give satisfactory service under radiation exposure. Fluoropolymers, Polyolefins, Polyketones and Nylons, as well as their compounds, are used in chemical resistance applications.

Engineering Thermoplastics, especially when compounded with reinforcing fibers and extruded into specially designed shapes, can provide the strength and stiffness of metals at much lighter weights. Most of the rigid Engineering Thermoplastics, especially when compounded with aramid, glass or graphite fibers, are used. PVC, ABS and Polystyrene are used for lowest cost. PPO, Nylon 66 and Polycarbonate are intermediate in cost and properties. Polysulfones, Polymides and Polyketones are used in the most demanding applications.
All of the well recognized rules of Mechanical Design apply to Engineering Thermoplastics. Glass and graphite fiber reinforced materials become completely anisotropic when extruded and this must always be kept in mind. The avoidance of stress risers is vital. Applications combining Anti-friction and /or Static Dissipation with strength are common. This is often a great opportunity to combine parts and simplify assembly with snap action.

Engineering Thermoplastics are inherently excellent electrical insulators. However, their other properties of high strength, low weight, low friction and environmental resistance have given compounders incentive to develop alloys and additive packages that make these materials conductive enough to dissipate static. This conductivity is permanent, not dependent on humidity, and cannot be rubbed off. Virtually all Engineering Thermoplastics are used in Static Dissipation applications. The operating environment and mechanical requirements are the criteria for choice of material. Conductive fillers/reinforcements often used include conductive organics, carbon powder and graphite fiber. Stainless steel fiber and aluminum flake are used for even greater conductivity.
Designing a structural part that is static dissipative almost always results in parts consolidation. Since each material behaves somewhat differently with each extruded shape, these designs must be approached cautiously.

Since they are organic materials, most thermoplastics will burn. When they do, they can generate noxious fumes and smoke. However, Engineering Thermoplastics are so valuable for use in aircraft, automobiles and all forms of public transit, and for use in homes and buildings of all sorts, that methods and materials have been developed that reduce these dangers. There are now resins such as the Polysulfones and Polketones that are extremely difficult to ignite and to maintain combustion. There are additive packages, some non-halogenated, that can be added to resins that reduce the chance of ignition, cause flame extinction, and greatly reduce smoke and fume generation.
Engineering Thermoplastics can maintain their desirable mechanical, electrical and decorative properties, while also becoming fire resistant.