Choosing the right plastic for your injection moulded part goes beyond strength and aesthetics. Whether you’re in automotive, medical, aerospace, or industrial manufacturing, the distinction between thermoplastics and thermosets could be the difference between success and failure.
At Stephens Plastic Mouldings, we help clients across the UK choose the right polymer based on the part’s application, durability needs, compliance requirements, and sustainability targets.
What Are Thermoplastics?
Thermoplastics (or thermosoftening plastics) are polymers that melt when heated and solidify once cooled. This makes them re-mouldable, recyclable, and ideal for projects requiring flexibility and rework.
1. Common Advantages:
- Recyclable and reprocessable.
- High impact resistance.
- Smooth surface finish.
- Good for complex, thin-walled parts.
2. Typical Uses:
- Medical components.
- Consumer packaging.
- Electrical housings.
- Automotive trims.
Explore our plastic injection moulding services to see how thermoplastics power UK manufacturing today.
What Are Thermosets?
Thermosetting plastics form an irreversible chemical bond during moulding. Once cured, the part cannot be melted or reshaped.
1. Key Advantages:
- Extremely high thermal stability.
- Excellent structural integrity.
- Resistant to deformation under stress.
- Often chemically and corrosion resistant.
2. Typical Applications:
- Electronics components.
- Engine housings.
- Aerospace brackets.
- High-voltage insulators.
If you’re designing for high-temperature or electrical environments, thermosets may be your ideal choice.
Head-to-Head Comparison: Thermoplastics vs Thermosets
| Property | Thermoplastics | Thermosets |
|---|---|---|
| Recyclability | Yes – can be re-melted | No – permanently crosslinked |
| Surface Finish | Smooth, glossy, highly detailed | Often more rugged |
| Heat Resistance | Moderate to high | Very high – ideal for heat-critical parts |
| Durability | High flexibility, moderate strength | High rigidity and tensile strength |
| Application Flexibility | Broad (medical, consumer, auto) | Niche (electrical, aerospace) |
Want a deeper dive into plastic types?
See our materials comparison for injection moulding to learn more.
Why Material Choice Matters for Your Moulding Project
- Speed vs Performance: Thermoplastics are ideal for high-speed, high-volume runs. Thermosets are better suited to demanding, niche applications.
- Sustainability Goals: Thermoplastics offer better recyclability and lower carbon output.
- Tooling Impact: Thermosets require hardened steel moulds and higher pressure. Thermoplastics can run with aluminium tools for faster prototyping.
At Stephens Plastic, we support both material categories through our design for manufacture (DFM) process, helping clients reduce risk and waste while improving functional performance.
FAQs for Electronics Buyers
1. Which is better for cost-effective production: thermoplastics or thermosets?
Thermoplastics are generally more economical for mass production, with lower tooling and material costs. They’re ideal for cost-sensitive, high-volume parts.
2. Can thermosets handle extreme heat better than thermoplastics?
Yes. Thermosets are chemically crosslinked, making them more stable at high temperatures, especially in automotive and electronic applications.
3. Are thermoplastics recyclable and eco-friendly?
Absolutely. Thermoplastics can be remoulded and reused, making them the sustainable choice for many projects. We even offer regrind support for selected jobs.
4. Can Stephens Plastic help me decide which plastic to use for my part?
Yes. We provide material consultation and prototyping to help you compare performance, compliance, and cost before production begins.
5. What industries typically use thermosets over thermoplastics?
Thermosets are favoured in electrical, aerospace, and high-stress mechanical applications where rigidity and temperature resistance are non-negotiable.
Not Sure Which Material to Use? We Can Help.
Whether you’re choosing glass-filled nylon, ABS, polyester, or a high-heat thermoset, Stephens Plastic Mouldings is your partner for technical advice, UK-based manufacturing, and material certainty.
To book a consultation or request a free quote
Contact Stephens Plastics Today
Email: sales@stephensplasticmouldings.co.uk
Phone: 0121 544 5808