DUROPLAST – Definition
In the group of polymers, thermosets, also known as duromers, are versatile stars whose advantages often outweigh those of thermoplastics.
As a competent partner, consultant and supplier, we have been supporting our customers from various technical markets, such as the automotive, supplier and electrical industries, with thermoset molded parts for years.
Reason enough to take a closer look at this ultra-modern and resilient material. What kind of material is thermoset? What properties do thermosets have? How are the properties and ingredients of thermoset connected?
We have the right answers to these and more detailed questions about our thermoset products.
If you have specific questions about our services, simply contact us directly here.
Thermosets, the exact name is duromers, are plastics that consist of three-dimensionally cross-linked polymer chains that harden and can no longer be deformed after hardening.
This key property makes thermosets the ideal material for replacing metal components. Thermosets are also genuine lightweight construction materials that can be used in a wide range of applications.
The list of product properties of thermosets includes high dimensional stability and dimensional stability as well as high thermal resilience. Even under challenging operating conditions, for example at high service temperatures (generally up to 200°C), thermosets retain their electrical and dielectric properties. Creep or a significant drop in mechanical properties, as is common with many thermoplastics at higher temperatures, is not found in a thermoset component.
Read more
There are specialized processes such as injection moulding, pressing or winding, which are used depending on the application and desired component geometry.
The processing methods are differentiated according to whether they are carried out under high pressure or low pressure. Production under high pressure takes place in a closed tool, here a further distinction is made between wet processes such as cold and hot pressing and dry processes using press mats.
Once they have been processed and cured, thermoset materials develop their full range of profitable, individual and specially desired properties. The preliminary products are usually synthetic resins mixed with fillers and colorants.
The end products are no longer deformable in their target design.
DUROPLAST components are characterized by extreme dimensional stability and resistance as well as high compressive strength thanks to their close-meshed cross-linking. Nevertheless, they can be individually adapted to your requirements using fillers, so-called additives such as glass beads, glass fibres, etc.
Read more
The specific properties of thermosets are largely determined by their ingredients.
The basic mechanical and thermal properties are determined by resins, which form the basis of the thermoset. Together with a specific combination of fillers, the characteristic properties of the corresponding thermoset plastics are then created. Epoxy resins, for example, offer high strength and chemical resistance, while phenolic resins are known for their heat resistance and mechanical properties.
Duroplast also contains hardeners to initiate the cross-linking reaction. These chemical compounds react with the resins. The choice of hardener influences the curing time, the final strength and the temperature resistance of the material.
Read more
The correct storage of thermoset precursors is crucial for their processability and the quality of the end product.
Some thermoset precursors and thermoset compounds themselves require a controlled storage temperature in order to at least reduce premature cross-linking.
Other thermosets, such as many phenolic resin compounds, are less sensitive to ambient temperatures and can be stored at room temperature. For these, non-temperature-controlled storage is sufficient. Nevertheless, they should be protected from moisture and direct sunlight in order to preserve their properties.
Batch fluctuations in the production of thermoset cannot always be avoided. They are caused, for example, by minor fluctuations in the raw materials. Inaccurate dosing or insufficient homogenization of the individual components can also result in varying material properties. It is therefore important to ensure that the material compounder adheres to strict rules and that these are monitored so that a defined, high-performance thermoset material is produced.
Ultimately, batch fluctuations are also caused by the process-related production of the thermoset compound.
Read more
No volume change during curing: This “zero shrinkage” is particularly important in applications where precise dimensional accuracy is required.
Shrinkage can be minimized or even completely eliminated by selecting suitable resin/hardener combinations and adding specific fillers. The adjustability of properties such as vibration behavior, hardness and processability is achieved through the targeted modification of the formulation and the process parameters.
It is also possible to produce thermoset plastic components with areas of zero degree demolding. If, for example, a cylindrical shape or an orthogonal surface to the demoulding direction is required, such component features can be realized with a thermoset. Zero degree demolding is a positive feature that is often used in the design of technical components.
Please do not hesitate to contact us about this special thermoset feature.
Do you have any questions about the specific adjustability of thermoset? Let us advise you in detail!
Thermosets are used in numerous industries around the world: from the automotive industry to electrical engineering, aerospace and the construction industry, to name just the largest customer sectors for thermosets.
Thermosets are being intensively researched and further developed in the European Union and worldwide.
Numerous universities (e.g. the TU Chemnitz https://www.tu-chemnitz.de/mb/KunstStTechn/startseite.php or the RWTH Aachen https://www.ikv-aachen.de , etc.) and research institutes are investigating new formulations and manufacturing processes in order to further improve the material properties and open up new areas of application.
Due to increasing requirements in power electronics and the increasing functional density in assemblies, such as in the drive unit of vehicles, or industrial applications, interest in functionalized plastics is growing. These can, for example, have thermally conductive, magnetic or mechanical properties. Thanks to the high possible filler content of often 80%, thermosets can be specifically adapted to various requirements.
That is why research interest is also high. Companies and universities, such as the FAU in Nuremberg with its Chair of Plastics Technology, are constantly working on new methods and optimization options in thermoset processing.
Among other things, the LKT at FAU is researching how process parameters can be systematically optimized in the production of functionalized thermoset compounds. The most important influencing variables in the injection molding process are also being investigated. Another research topic is the development of processes for the production of media-tight systems by overmolding with thermoset.
Read more
Thermoset is currently used in structural components such as covers, housings for control units and pumps or brake system components.
In the electrical industry, thermoset products can be found in switches, sockets and insulators, as they offer stable electrical insulation values even under heat and pressure.
As part of the electrification of drives and their control systems, we are seeing a significant increase in the use of thermoset plastics.
Read more
Thermosets are indispensable plastics for numerous demanding applications. Their special structure and the permanent cross-linking of the molecules give them high strength and resistance to heat and high temperatures - properties that hardly any other lightweight material can offer under these commercial conditions.
The production of our thermosets enables customized solutions for a wide range of requirements. If you would like to find out more about the advantages of thermosets or make the best choice of material for your project, arrange a consultation with the experts at Baumgarten now - we will be happy to help you!
Here it goes direct to your contact at Baumgarten, the experts for thermoset molded parts!
EN 
DE