{"id":11627,"date":"2023-03-23T10:01:33","date_gmt":"2023-03-23T17:01:33","guid":{"rendered":"https:\/\/www.fictiv.com\/?post_type=cpt_blog&#038;p=11627"},"modified":"2023-03-30T08:49:25","modified_gmt":"2023-03-30T15:49:25","slug":"polystyrene-injection-molding","status":"publish","type":"cpt_blog","link":"https:\/\/www.fictiv.com\/articles\/polystyrene-injection-molding","title":{"rendered":"Polystyrene Injection Molding"},"content":{"rendered":"\n<p>Polystyrene (PS) is a commodity thermoplastic with an amorphous structure. It has excellent resistance to gamma rays and, therefore, supports sterilization by radiation. Polystyrene plastics can be either transparent or opaque, and unmodified polystyrene is clear, rigid, brittle and moderately strong. Also, polystyrene is cost-effective and supports <a href=\"https:\/\/www.fictiv.com\/injection-molding-service#processes-availa\">injection molding<\/a>.<\/p>\n\n\n\n<p>Grades of polystyrene include GPPS and HIPS. General purpose polystyrene (GPPS) is naturally transparent and relatively brittle. High impact polystyrene (HIPS) contains additives that increase toughness but with a loss of transparency. When polystyrene is produced as a foam, types include extruded polystyrene (XPS) and expanded polystyrene (EPS).&nbsp;&nbsp;&nbsp;&nbsp;<\/p>\n\n\n\n<figure class=\"wp-block-image size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"500\" height=\"440\" data-src=\"https:\/\/www.fictiv.com\/wp-content\/uploads\/2023\/03\/Polystyrene.jpeg\" alt=\"Polystyrene\" class=\"wp-image-11629 lazyload\"\/><\/figure>\n\n\n\n<p><em>Figure 1: Clear polystyrene is used in blood dilution lab vials. Image Credit: <\/em><a href=\"https:\/\/www.sks-science.com\/plastic-laboratory-vials-p-10037.html\"><em>SKS Science<\/em><\/a><\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Advantages of Polystyrene Injection Molding<\/h2>\n\n\n\n<p>Polystyrene has a number of advantages that make it an ideal material for applications ranging from injection molded automotive parts to medical products. This thermoplastic has the following characteristics:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Transparent<\/li>\n\n\n\n<li>Tough and rigid<\/li>\n\n\n\n<li>Lightweight<\/li>\n\n\n\n<li>Moisture resistant<\/li>\n\n\n\n<li>Impact resistant<\/li>\n\n\n\n<li>Dimensionally stable<\/li>\n\n\n\n<li>Radiation resistant<\/li>\n<\/ul>\n\n\n\n<h3 class=\"wp-block-heading\">Transparent<\/h3>\n\n\n\n<p>In its pure form (GPPS), polystyrene is transparent with 90% light transmissibility. It provides a relatively inexpensive alternative to other transparent plastics, such as polycarbonate or acrylic. GPPS can be brittle, however, and that\u2019s why HIPS is sometimes used instead.&nbsp;&nbsp;<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Tough and Rigid<\/h3>\n\n\n\n<p>HIPS polystyrene contains between 5% and 10% butadiene rubber so that it\u2019s tougher and more rigid. Applications include automotive instrument panels and computer housings.&nbsp;<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Lightweight<\/h3>\n\n\n\n<p>Polystyrene is a lightweight plastic, which is why it\u2019s often used in food containers, consumer packaging, and even ceiling-mounted smoke detectors.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Moisture Resistant<\/h3>\n\n\n\n<p>Polystyrene is highly resistant to moisture, which makes it a good choice for plastic cutlery, and laboratory and scientific products such as test tubes and petri dishes.&nbsp;<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Impact Resistant<\/h3>\n\n\n\n<p>Although GPPS has relatively low impact strength, HIPS is strong enough to be used for protective packaging and in repeated-use applications such as cafeteria food trays.&nbsp;<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Dimensionally Stable<\/h3>\n\n\n\n<p>Injected molded polystyrene has excellent dimensional stability. This is due, in part, to its amorphous nature, which reduces shrinkage after injection molding. Also, because polystyrene doesn\u2019t absorb water, it won\u2019t swell and increase in size.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Radiation Resistant<\/h3>\n\n\n\n<p>Polystyrene has a kilogray (kGy) value of 10,000, which means it absorbs very little radiation. This radiation resistance is due to the benzene ring in polystyrene\u2019s molecular formula. Consequently, polystyrene can be subjected to radiation for sterilization purposes and won\u2019t suffer a significant degradation of mechanical properties.<\/p>\n\n\n\n<figure class=\"wp-block-image size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"768\" height=\"512\" data-src=\"https:\/\/www.fictiv.com\/wp-content\/uploads\/2023\/03\/pexels-rodnae-productions.jpeg\" alt=\"Polystyrene injection molding design\" class=\"wp-image-11630 lazyload\" data-srcset=\"https:\/\/www.fictiv.com\/wp-content\/uploads\/2023\/03\/pexels-rodnae-productions.jpeg 768w, https:\/\/www.fictiv.com\/wp-content\/uploads\/2023\/03\/pexels-rodnae-productions-600x400.jpeg 600w\" sizes=\"auto, (max-width: 768px) 100vw, 768px\" \/><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\">Polystyrene Injection Molding Design Guidelines<\/h2>\n\n\n\n<p>Polystyrene is relatively easy to injection mold, but it\u2019s still important for part designers to follow guidelines in the following areas:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Wall thickness<\/li>\n\n\n\n<li>Ribs &amp; stiffeners<\/li>\n\n\n\n<li>Radii<\/li>\n\n\n\n<li>Draft angle<\/li>\n\n\n\n<li>Part tolerances<\/li>\n<\/ul>\n\n\n\n<p>If you\u2019re looking for more injection molding design tips and insights for polystyrene and a variety of other materials, <a href=\"https:\/\/www.fictiv.com\/ebooks\/get-smart-on-injection-molding\">download the Fictiv Injection Molding Design Guide.<\/a><\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Wall Thickness<\/h3>\n\n\n\n<p>Injection molded polystyrene should have a <a href=\"https:\/\/www.fictiv.com\/articles\/wall-thickness-reco\">wall thickness<\/a> between 0.76 and 5.1 mm. If the change between sections is gradual, a wall thickness variation of 25% can be achieved.&nbsp;&nbsp;<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Ribs &amp; Stiffeners<\/h3>\n\n\n\n<p>To prevent the formation of sink marks, make <a href=\"https:\/\/www.fictiv.com\/articles\/best-practices-for-adding-ribs-and-gussets-to-3d-printed-parts-for-structural-integrity\">ribs<\/a> 60% to 50% of the supported wall\u2019s thickness.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Radii<\/h3>\n\n\n\n<p>The recommended radius depends on the type of polystyrene \u2014 because GPPS is more brittle than HIPS, a radius that\u2019s too small is a potential source of failure. In general, a minimum radius of 25% of the wall thickness is recommended. For high-strength parts, use a radius of up to 75% instead.&nbsp;<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Draft Angle<\/h3>\n\n\n\n<p>Polystyrene has a low shrinkage rate and is highly rigid. To ensure part ejection, apply <a href=\"https:\/\/www.fictiv.com\/articles\/draft-and-texture-in-plastic-injection-molded-parts\">draft angles<\/a> between 0.5 and 1% and a polished finish to your molds to aid in part ejection.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Part Tolerances<\/h3>\n\n\n\n<p><a href=\"https:\/\/www.fictiv.com\/articles\/injection-molding-tolerances-an-in-depth-look\">Part tolerances<\/a> can be either commercial or fine, with fine tolerances having tighter values. <a href=\"https:\/\/www.plasticstoday.com\/design-polystyrene-part-design\">For example<\/a>, a .125-inch-thick part that\u2019s 1 inch long can be held to a commercial length tolerance of \u00b1.003 in\/in. A fine tolerance would be \u00b1.002 in\/in.Tighter tolerance requirements increase the cost of the mold and of injection molded parts, however.&nbsp;<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Polystyrene Material Properties&nbsp;<\/h2>\n\n\n\n<p>Table 1 below lists some average physical, mechanical, and molding properties of various polystyrene injection molding grades:<\/p>\n\n\n\n<figure class=\"wp-block-table\"><table><tbody><tr><td><\/td><td><\/td><td><a href=\"https:\/\/matweb.com\/search\/DataSheet.aspx?MatGUID=df6b1ef50ce84e7995bdd1f6fd1b04c9&amp;ckck=1\">Unreinforced PS<\/a><\/td><td><a href=\"https:\/\/matweb.com\/search\/DataSheet.aspx?MatGUID=be2fb354bdd54f4ba07710a547e1cb02\">Impact Modified PS<\/a><\/td><td><a href=\"https:\/\/matweb.com\/search\/DataSheet.aspx?MatGUID=873cf14a45b8416ab0d6f4e2fa24e61e\">Transparent PS<\/a><\/td><td><a href=\"https:\/\/matweb.com\/search\/DataSheet.aspx?MatGUID=9b8191c61d0d49e0857df49681644048\">Heat Resistant PS<\/a><\/td><\/tr><tr><td><strong>Physical<\/strong><\/td><td><strong>Density (g\/cm3)<\/strong><\/td><td>0.857<\/td><td>1.05<\/td><td>1.04<\/td><td>1.05<\/td><\/tr><tr><td><\/td><td><strong>Linear Mold Shrinkage Rate (cm\/cm)<\/strong><\/td><td>0.00509<\/td><td>0.0060<\/td><td>0.00539<\/td><td>0.00557<\/td><\/tr><tr><td><\/td><td><strong>Rockwell Hardness (R)<\/strong><\/td><td>100<\/td><td>94.8<\/td><td>121<\/td><td>105<\/td><\/tr><tr><td><strong>Mechanical<\/strong><\/td><td><strong>Tensile Strength at Yield (MPa)<\/strong><\/td><td>43.7<\/td><td>25.9<\/td><td>43.6<\/td><td>45.9<\/td><\/tr><tr><td><\/td><td><strong>Elongation at break (%)<\/strong><\/td><td>25.8<\/td><td>44.8<\/td><td>3.14<\/td><td>9.74<\/td><\/tr><tr><td><\/td><td><strong>Flexural Modulus (GPa)<\/strong><\/td><td>3.47<\/td><td>2.14<\/td><td>3.11<\/td><td>2.99<\/td><\/tr><tr><td><\/td><td><strong>Flexural Yield&nbsp; Strength (MPa)<\/strong><\/td><td>69.2<\/td><td>54<\/td><td>76.2<\/td><td>82<\/td><\/tr><tr><td><strong>Injection Molding<\/strong><\/td><td><strong>Drying Temperature (\u00b0C)<\/strong><\/td><td>92.2<\/td><td>78<\/td><td>76.7<\/td><td>76.2<\/td><\/tr><tr><td><\/td><td><strong>Melt Temperature (\u00b0C)<\/strong><\/td><td>250<\/td><td>216<\/td><td>220<\/td><td>215<\/td><\/tr><tr><td><\/td><td><strong>Mold Temperature (\u00b0C)<\/strong><\/td><td>69.5<\/td><td>49.6<\/td><td>52<\/td><td>52.9<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n<p><em>Table 1: Polystyrene Material Properties<\/em><\/p>\n\n\n\n<figure class=\"wp-block-image size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"720\" height=\"480\" data-src=\"https:\/\/www.fictiv.com\/wp-content\/uploads\/2023\/03\/worker-operating-plastic-injection-molding-press.jpeg\" alt=\"Polystyrene injection molding\" class=\"wp-image-11631 lazyload\" data-srcset=\"https:\/\/www.fictiv.com\/wp-content\/uploads\/2023\/03\/worker-operating-plastic-injection-molding-press.jpeg 720w, https:\/\/www.fictiv.com\/wp-content\/uploads\/2023\/03\/worker-operating-plastic-injection-molding-press-600x400.jpeg 600w\" sizes=\"auto, (max-width: 720px) 100vw, 720px\" \/><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\">Polystyrene Material Processing<\/h2>\n\n\n\n<p><a href=\"https:\/\/www.fictiv.com\/injection-molding-service\">Plastic injection molding<\/a> with polystyrene successfully requires choosing the right processing parameters. Here are some of the most important ones to consider:&nbsp;<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Injection pressure<\/li>\n\n\n\n<li>Moisture resistance<\/li>\n\n\n\n<li>Temperature control<\/li>\n\n\n\n<li>Viscosity<\/li>\n\n\n\n<li>Shrinkage<\/li>\n<\/ul>\n\n\n\n<h3 class=\"wp-block-heading\">Injection Pressure<\/h3>\n\n\n\n<p>Injection pressures for polystyrene can range from 100 to 200 Bar, and maintaining the pressure after injection can reduce overall shrinkage rates.&nbsp;<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Moisture Resistance<\/h3>\n\n\n\n<p>Polystyrene resists moisture and generally does not need to be dried prior to molding. However, in cases where the resin may contain recycled material, or if the environment has high humidity, then pre-drying is recommended.&nbsp;<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Temperature Control<\/h3>\n\n\n\n<p>Polystyrene has a relatively high melting point of around 217\u00b0C, depending on the material grade. This is higher than other <a href=\"https:\/\/www.fictiv.com\/articles\/the-ten-most-common-plastic-injection-molding-materials\">common injection molding plastics<\/a>, such as <a href=\"https:\/\/www.fictiv.com\/articles\/polyethylene-injection-molding\">polyethylene<\/a>. Despite its high melting temperature, polystyrene begins to soften between 70\u00b0C and 106\u00b0C.&nbsp;<\/p>\n\n\n\n<p>Increased temperature may improve moldability, but can have a negative effect on glossiness and material strength. In addition, higher temperatures result in longer cycle times since molded parts need more time to cool before ejection. For best results, keep temperatures below 250\u00b0C.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Viscosity<\/h3>\n\n\n\n<p>Polystyrene has a low viscosity. This makes it ideal for injection molded parts with small features since material moves more easily throughout the mold. Different grades of polystyrene have different viscosities, however, and temperatures should be adjusted accordingly.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Shrinkage<\/h3>\n\n\n\n<p>Injection molded polystyrene has low shrinkage values, typically between 0.4% and 0.7%. In some cases, however, it\u2019s possible to achieve shrinkage less than 0.4%, such as near the sprue where there are high follow-up pressures. Only 10% of total shrinkage occurs after part ejection.&nbsp;<\/p>\n\n\n\n<p>Succeeding With Polystyrene Injection Molding<\/p>\n\n\n\n<p>Polystyrene is used in a wide range of applications because this injection molding material is lightweight, relatively inexpensive, and moisture resistant. Provided that proper part design and processing guidelines are followed, PS is relatively easy to injection mold.<\/p>\n\n\n\n<p>Polystyrene is a commonly used injection molding plastic, but a good plan and skilled production partner are critical to avoid the added costs and risks that come with inadequate drying or improper processing methods. Fictiv has the global manufacturing network and production experts you need to get quality injection molded parts, no matter how complex your designs. And we have the skills and know-how to support you from part design through prototyping and production.<\/p>\n\n\n\n<p><a href=\"https:\/\/app.fictiv.com\/signup\">Create your free Fictiv account<\/a> and request an injection molding quote today \u2014 we mold complex parts at ridiculous speeds!<\/p>\n","protected":false},"excerpt":{"rendered":"<p>Polystyrene (PS) is a commodity thermoplastic with an amorphous structure. It has excellent resistance to gamma rays and, therefore, supports sterilization by radiation. Polystyrene plastics can be either transparent or opaque, and unmodified polystyrene is clear, rigid, brittle and moderately strong. Also, polystyrene is cost-effective and supports injection molding. Grades of polystyrene include GPPS and [&hellip;]<\/p>\n","protected":false},"author":145,"featured_media":11629,"parent":0,"menu_order":0,"template":"","fictiv_role":[],"fictiv_topic":[],"fictiv_industry":[],"fictiv_manufacturing_process":[51],"coauthors":[159],"class_list":["post-11627","cpt_blog","type-cpt_blog","status-publish","has-post-thumbnail","hentry"],"aioseo_notices":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO Premium plugin v24.2 (Yoast SEO v24.2) - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>Polystyrene Injection Molding | PS Plastic | Fictiv<\/title>\n<meta name=\"description\" content=\"Polystyrene injection molding is used to produce lightweight parts that are moisture and radiation resistant. 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