The application of engineering plastics in the mechanical industry has significantly promoted equipment lightweighting, wear resistance improvement, and complex functional integration. Its high mechanical performance, corrosion resistance, and design flexibility have become key advantages in replacing traditional metals. The following is a detailed analysis of the core application areas, technological innovation, and future trends of engineering plastics in the machinery industry:
1、 Core application areas and material selection
Transmission and moving parts
Gears and bearings: POM has a low friction coefficient (dynamic friction coefficient 0.1-0.3) and wear resistance, replacing metal gears (such as injection molding machine transmission gears), reducing weight by 40% and requiring no lubrication.
Chain guide rail: PA66 reinforced material is used for automation equipment guide rail, which is wear-resistant and reduces noise.
Precision gears: PEEK is heat-resistant (260 ℃) and chemically resistant, used for high load gears in oil drilling equipment.
Materials: Polyoxymethylene (POM), Polyamide (PA, Nylon), Polyether Ether Ketone (PEEK)
Application:
Wear resistant and sealing components
Sealing rings and gaskets: PTFE's corrosion resistance (strong acid and alkali resistance) is used for chemical machinery seals, extending their lifespan by three times.
Wear resistant lining plate: UHMWPE has 6 times the wear resistance of carbon steel and is used as a lining plate for conveyor belts in mining machinery.
Materials: Polytetrafluoroethylene (PTFE), Ultra High Molecular Weight Polyethylene (UHMWPE)
Application:
Structural support and framework
Robot arm housing: PC/GF combines high rigidity and impact resistance, and can withstand factory environmental vibrations.
Lightweight bracket: LGF-PP replaces metal brackets (such as packaging machinery frames), reducing weight by 50% and being fatigue resistant.
Materials: Glass fiber reinforced polycarbonate (PC/GF), long glass fiber reinforced polypropylene (LGF-PP)
Application:
High temperature and corrosion-resistant environment
High temperature pump valve: PPS is resistant to temperatures of 260 ℃ and acid and alkali, and is used as a valve for chemical reaction vessels.
Vacuum equipment components: PI film is used as a high-temperature insulation layer for semiconductor machinery, capable of withstanding instantaneous high temperatures up to 500 ℃.
Materials: Polyphenylene sulfide (PPS), Polyimide (PI)
Application:
2、 Core advantages and technological breakthroughs
Lightweight and energy-saving
The density of engineering plastics is 1/4-1/7 of metals, for example, POM gears can reduce weight by 40% and reduce equipment inertia energy consumption by 15%.
Case: The injection molding machine template is made of carbon fiber reinforced PA6, which weighs only 1/5 of the steel template, improving the motion response speed.
Self lubrication and maintenance free
PTFE or graphite filling materials achieve oil-free lubrication, reducing downtime maintenance frequency.
Innovation: DuPont Delrin AF contains PTFE lubricant, reducing the friction coefficient to 0.04, suitable for high-speed conveyor belt bearings.
Corrosion resistance and long lifespan
Engineering plastics are resistant to acid, alkali, and salt spray corrosion. For example, PPS has a strength retention rate of>90% after soaking in 10% sulfuric acid for 1000 hours.
Case: The pump body of seawater desalination equipment uses PEEK instead of stainless steel, which extends the service life to more than 10 years.
Integrated molding of complex structures
3D printing technology enables topology optimization structures that are difficult to achieve through traditional processing, such as bionic lightweight robotic arm joints.
Case: EOS's PA2200 powder printed gearbox integrates cooling channels, increasing heat dissipation efficiency by 30%.
3、 Market Trends and Challenges
Market size and growth
The global market size of engineering plastics for machinery is expected to reach approximately 7.8 billion US dollars in 2023, and is projected to reach 12.1 billion US dollars by 2030 (CAGR 6.2%).
Driving factors: Industrial automation (with a 20% increase in demand for robotic arms), new energy equipment (upgrading materials for wind power gearboxes).
Technology Trends
Nanocomposite materials: Adding nano silica enhances the impact resistance of PA6 (increasing notch impact strength by 50%).
Biobased materials: BASF Ultramid ® Balance contains 60% bio based PA and is used for food machinery components.
challenge
Cost pressure: The price of PEEK is about $100/kg, and costs need to be reduced through large-scale production.
Recycling challenge: The recycling rate of thermosetting composite materials (such as carbon fiber reinforced plastics) is less than 10%, and chemical depolymerization technology needs to be developed.
4、 Typical Case Analysis
Agricultural Machinery: PA12 is used for harvester chain guides, which are resistant to sand and dust wear and noise reduction.
Textile machinery: POM gears replace copper alloys to reduce lubricant pollution and adapt to dust-free workshop environments.
3D printing machinery: PEI (ULTRAM 1010) high-temperature resistant print head, capable of withstanding 400 ℃ molten plastic spraying.
5、 Future prospects
Intelligent materials: Integrated sensors (such as carbon nanotube conductive PA) achieve self-monitoring of device status.
Extreme environmental applications: PEEK based composite materials are used for deep well drilling (pressure resistance of 100MPa, temperature resistance of 300 ℃).
Circular Economy: Chemical Recycling Technologies (such as Teijin EcoCircle) ™） Realize closed-loop regeneration of PA66 and reduce carbon footprint.
Through continuous innovation, engineering plastics are becoming the core material for efficient, environmentally friendly, and intelligent machinery industry. In the future, they will lead the industry transformation in the direction of high performance, functional integration, and sustainable development.