High-Performance Plastics

Design Purpose

High-performance plastics were engineered to replace metal components in environments where weight reduction, chemical resistance, and thermal stability are critical. Their design intent focuses on achieving high mechanical reliability while resisting deformation under heat, oxidation, or prolonged stress. In additive manufacturing, these materials are used to produce complex structures that demand metal-like performance without the associated weight or machining cost. Industries rely on them for precision housings, functional brackets, medical components, high-temperature insulators, and chemical-resistant systems. Their ability to maintain performance under extreme conditions allows engineers to expand design possibilities in aerospace, automotive, energy, and medical applications.

Chemical Composition (Generic High-Performance Polymer Families)

Physical Properties (General Range)

Mechanical Properties (General Range)

Key Material Characteristics

• Exceptional high-temperature resistance suitable for demanding aerospace and industrial environments

• Superior mechanical strength and stiffness comparable to lightweight metals

• Excellent chemical resistance to solvents, fuels, acids, and industrial chemicals

• Outstanding dimensional stability under thermal cycling and mechanical loads

• Low moisture absorption ensures reliable performance in humid or aquatic environments

• Excellent wear resistance suitable for sliding, rotating, or friction-intensive applications

• High dielectric strength ideal for electrical insulation components

• Biocompatibility options available for medical and food-grade applications

• Compatibility with precision additive manufacturing processes enabling complex geometries

• Lower weight than metal alternatives while maintaining structural reliability

• Strong fatigue resistance for long-life mechanical assemblies

• Smooth surface finish suitable for consumer and engineering applications

Manufacturability in Different Processes

• FDM/FFF printing: High-performance plastics require elevated nozzle and chamber temperatures, making them suitable for functional prototypes and engineering-grade components.

• SLS: Powder-based high-temperature polymers enable isotropic strength and excellent mechanical uniformity.

• SLA substitutes: High-strength, tough resin can complement precision applications that require rigid performance.

• CNC machining: These plastics exhibit clean cutting behavior with proper tooling and coolant strategies.

• Injection molding: While suitable, tooling costs are higher; additive manufacturing offers a cost-effective alternative for low-volume production.

• Hybrid manufacturing: Components can be integrated with metal frames to achieve lightweight structural solutions.

• Prototype validation: High-performance plastics seamlessly integrate into Neway’s 3D printing service workflows for rapid testing and product iteration.

Suitable Post-Processing Methods

• Thermal annealing to relieve internal stresses and improve crystallinity

• Dimensional finishing through light machining, sanding, or polishing

• Chemical smoothing for select polymer families

• Dyeing or pigmentation for custom appearance

• Sterilization for medical and laboratory applications

• Structural testing under standardized material testing procedures

• Assembly preparation using threaded inserts or adhesive bonding

• Surface sealing for improved chemical and moisture resistance

Common Industries and Applications

• Aerospace: high-strength brackets, ducting components, lightweight housings

• Automotive: thermal insulators, underhood components, structural connectors

• Energy: chemical-resistant fittings, electrical insulation parts, thermal shields

• Medical: surgical tool housings, sterilizable components, diagnostic device parts

• Industrial machinery: gears, wear-resistant guides, structural fixtures

• Electronics: heat-resistant casings, connectors, precision insulating components

When to Choose This Material

• When metal-like performance is required without the added weight

• When parts must withstand high temperatures, chemicals, or mechanical stress

• When dimensional stability under extreme conditions is essential

• When complex geometries exceed the limitations of injection molding

• When low moisture absorption and long-term stability are critical

• When the product demands clean, precise tolerances and superior durability

• When lightweight structural components must perform under continuous load

• When the application requires biocompatibility or sterilization capability