In this article, Protolabs explores how recycled materials can be used in injection moulding to replace traditional materials in various applications.
Reliability and Quality Concerns with Recycled Materials in Injection Moulding
In the past, concerns about using sustainable materials in manufacturing have centred on the perceived reliability and quality of these materials. However, on a technical level, recycled materials may even outperform their traditional counterparts. Manufacturers frequently produce parts that do not utilise the full mechanical properties of a material, enabling them to switch to a recycled material without sacrificing performance due to a built-in contingency.
Protolabs’ Recycled Materials for Injection Moulding
Protolabs offers three recycled materials for its injection moulding service, which it compares here to traditional options:
Gebalon PC Ultimate for Electrical and Electronics Parts
The Gebalon PC Ultimate G0 FR Black is a polycarbonate (PC) material commonly used for technical moulded parts, particularly in the electrical and electronics industries. Applications include components such as switches, connectors, and boxes. Gebalon offers a heat deflection of 136°C and tensile strength of 2,200 MPa, while a standard PC material, like Iupilon S3001R, has a slightly higher heat deflection at 140°C and a tensile modulus of 2,400 MPa. Gebalon has a superior flammability grade of V0 at 1.5mm, in contrast to Lupilon’s V2 rating at the same thickness.
Gebamid PA6 B for Mechanical and Automotive Applications
Gebamid PA6 B GF 30% Black is a glass-filled nylon (PA6) material widely used in the mechanical, electrical, and automotive sectors. Gebamid boasts a heat deflection of 191°C and a tensile modulus of 7,500 MPa, compared to its counterpart, Nylon 6 Radilon S RV300 30% GF Black, which has a higher heat deflection of 215°C and a tensile modulus of 9,600 MPa. While it shows a lower tensile modulus and a wider shrinkage ratio, Gebamid’s water absorption levels remain consistent with the standard.
Gebablend 85 for Consumer Electronics and Automotive Use
The Gebablend 85 Black, an ABS/PC material, is used in diverse applications, including consumer electronics, machine construction, sports equipment, and automotive parts. It provides a heat deflection of 128°C and a tensile modulus of 2,400 MPa, aligning well with the standard alternative, Bayblend T65 XF Black, which has a heat deflection of 122°C and matches its tensile strength of 2,400 MPa. Although Gebablend 85 shows a slight disadvantage in shrink rate (0.45-0.8% vs. Bayblend’s 0.5-0.7%), it offers a higher flow rate.
CNC Machining with Recycled Materials for Sustainable Manufacturing
To further support sustainable practices, Protolabs has introduced two new recycled plastic materials to its CNC machining service: rPOM-C (recycled Polyoxymethylene Copolymer) and rPEEK (recycled Polyetheretherketone). This development enables users to prototype without relying on virgin materials. These recycled options not only help conserve resources and support the circular economy but also maintain equivalent mechanical and thermal properties to their non-recycled counterparts. Companies can incorporate these options to reduce environmental impact and comply with sustainability regulations.
Future Potential of Recycled Materials in Greener Manufacturing
The technical capabilities of recycled materials make them a viable, sustainable alternative to traditional materials. While not every application may suit sustainable materials due to specific performance requirements, the exploration of sustainable manufacturing methods offers manufacturers a promising path toward a more eco-friendly future. By embracing sustainable materials in injection moulding and CNC machining, Protolabs is paving the way for greener, more sustainable manufacturing solutions.
