Polypropylene is a very useful plastic for injection molding.

In addition to the conventional plastic

applications, polypropylene also lends itself well in fiber applications, which give it even a wider
range of uses that goes beyond just injection molding, including: ropes, carpets, upholstery,
clothing, and the like. Polypropylene has gained popularity since it was first synthesized in the
50s. According to some reports, the current global demand for the material generates an annual
market of about 45 million metric tons and it is estimated that the demand will rise to
approximately 62 million metric tons by 2020. The major end users of polypropylene are the
packaging industry, which consumes about 30% of the total, followed by the electrical and
equipment manufacturing, which uses about 13% each. Household appliances and automotive
industries both consume 10% each and construction materials follows with 5% of the market.
Other applications together make up the rest of the global polypropylene consumption.
POLYPROPYLENE AS AN INJECTION MOLDING PLASTIC
Polypropylene is a very popular material in the injection molding world; this popularity is due to it
being a very moldable material. Its versatility, wide range of uses, and unique properties are
among those reasons. Polypropylene is easy to mold despite its semi-crystalline nature, and it
flows very well because of its low melt viscosity. This property significantly enhances the rate at
which you can fill up a mold with the material. The rate should not be set too high, however, to
ensure good surface finish and to avoid defects such as voids, weld lines, and flow fronts. The
melt temperature of polypropylene can be anywhere between 200oC (392oF) to 250oC (482oF),
although it can go higher depending on the grade of polypropylene and the kind of additives it
contains. Shrinkage in polypropylene is about 1% but can vary based on a number of factors,
including holding pressure, holding time, melt temperature, mold wall thickness, mold
temperature, and the percentage and type of additives.
POLYPROPYLENE AS A CNC MACHINABLE PLASTIC
Polypropylene has gained a reputation as a material that cannot be machined. This is because
it has a low annealing temperature, which means that it starts to deform under heat. Because it
is a very soft material in general, it requires an extremely high skill level to be cut with precision;
Creative Mechanisms has been successful in doing so. Our teams can use a CNC machine and
cut the polypropylene cleanly and with extremely great detail.
In addition, we are able to create living hinges with polypropylene that have thickness as little as
.010 inches. Making living hinges is a difficult endeavor on its own, which makes using a difficult
material like polypropylene even more impressive.
POLYPROPYLENE PROS AND CONS
Polypropylene, like every other polymer, has advantages and disadvantages that make it more
suitable for certain uses than others.
Advantages of polypropylene:

It is a relatively inexpensive material

It possesses high flexural strength because of its semi-crystalline nature

It has a low coefficient of friction It is very resistant to moisture

It has good chemical resistance over a wide range of bases and acids

It possesses good fatigue resistance It has good impact strength

It has a good resistance to electricity and is thus a good electrical insulator

It is more easily repaired from damage

Disadvantages of polypropylene:

It has a high thermal expansion coefficient which limits its high temperature applications

It is susceptible to UV degradation It has poor resistance to chlorinated solvents and

aromatics

It is known to be difficult to paint as it has poor bonding properties

It has a high flammability

It is susceptible to oxidation

Despite its shortcomings, polypropylene is a great material. It has a unique blend of qualities
that arent found in any other material, which makes it an ideal choice for many projects.
Polypropylene Advantages
Polypropylene offers many different advantages. These advantages allow it to be used for a
wide variety of different products and uses, from high heat to cold weather and more. What are
some of these advantages?
-Low cost makes it budget friendly for a wide number of uses
-Has a moderate strength and stability
-Has flexibility, which makes it easy to mold into different shapes
-Colorfast, which means that any colors will stay bright and beautiful
-Resistant to fatigue, which allows it to be used for things such as water bottle hinges and
spouts
-Offers good insulation for pipes, cables, and more
-Chemically resistant to most oils and solvents

-Excellent impact strength

-Low coefficient of friction
-Excellence moisture resistance
-High temperature resistance, which means it can be used in laboratories
Chemical and physical properties
POLYPROPYLENE
Polypropylene is in many aspects similar to polyethylene, especially in solution behaviour and
electrical properties. The additionally present methyl group improves mechanical properties and
thermal resistance, while the chemical resistance decreases.[2]:19 The properties of
polypropylene depend on the molecular weight and molecular weight distribution, crystallinity,
type and proportion of comonomer (if used) and the isotacticity.[2]:24
Mechanical properties
The density of PP is between 0.895 and 0.92 g/cm. Therefore, PP is the commodity plastic with
the lowest density. With lower density,moldings parts with lower weight and more parts of a
certain mass of plastic can be produced. Unlike polyethylene, crystalline and amorphous
regions differ only slightly in their density. However, the density of polyethylene can significantly
change with fillers.[2]:24
The Young's modulus of PP is between 1300 and 1800 N/mm.
Polypropylene is normally tough and flexible, especially when copolymerized with ethylene. This
allows polypropylene to be used as an engineering plastic, competing with materials such
as acrylonitrile butadiene styrene (ABS). Polypropylene is reasonably economical.
Polypropylene has good resistance to fatigue.[3]:307
Thermal properties
The melting point of polypropylene occurs at a range, so a melting point is determined by finding
the highest temperature of a differential scanning calorimetry chart. Perfectly isotactic PP has a
melting point of 171 C (340 F). Commercial isotactic PP has a melting point that ranges from
160 to 166 C (320 to 331 F), depending on atactic material and crystallinity. Syndiotactic PP

with a crystallinity of 30% has a melting point of 130 C (266 F).[3] Below 0 C, PP becomes
brittle.[4]:247
The thermal expansion of polypropylene is very large, but somewhat less than that of
polyethylene.[4]
Chemical properties
Polypropylene is at room temperature resistant to fats and almost all organic solvents, apart
from strong oxidants. Non-oxidizing acids and bases can be stored in containersmade of PP. At
elevated temperature, PP can be solved in of low polarity solvents
(e.g. xylene, tetralin and decalin). Due to the tertiary carbon atom PP is chemically less resistant
than PE (see Markovnikov rule).[5]
Most commercial polypropylene is isotactic and has an intermediate level
of crystallinity between that of low-density polyethylene (LDPE) and high-density
polyethylene (HDPE). Isotactic & atactic polypropylene is soluble in P-xylene at 140 C. Isotactic
precipitates when the solution is cooled to 25 C and atactic portion remains soluble in P-xylene.
The melt flow rate (MFR) or melt flow index (MFI) is a measure of molecular weight of
polypropylene. The measure helps to determine how easily the molten raw material will flow
during processing. Polypropylene with higher MFR will fill the plastic mold more easily during
the injection or blow-molding production process. As the melt flow increases, however, some
physical properties, like impact strength, will decrease.
There are three general types of polypropylene: homopolymer, random copolymer, and block
copolymer. The comonomer is typically used with ethylene. Ethylene-propylene rubber
or EPDM added to polypropylene homopolymer increases its low temperature impact strength.
Randomly polymerized ethylene monomer added to polypropylene homopolymer decreases the
polymer crystallinity, lowers the melting point and makes the polymer more transparent.
Degradation
Polypropylene is liable to chain degradation from exposure to heat and UV radiation such as
that present in sunlight. Oxidation usually occurs at the tertiary carbon atom present in
every repeat unit. A free radical is formed here, and then reacts further with oxygen, followed by
chain scission to yield aldehydes and carboxylic acids. In external applications, it shows up as a
network of fine cracks and crazes that become deeper and more severe with time of exposure.
For external applications, UV-absorbing additives must be used.Carbon black also provides
some protection from UV attack. The polymer can also be oxidized at high temperatures, a

common problem during molding operations. Anti-oxidantsare normally added to

prevent polymer degradation. Microbial communities isolated from soil samples mixed with
starch have been shown to be capable of degrading polypropylene.[6] Polypropylene has been
reported to degrade while in human body as implantable mesh devices. The degraded material
forms a tree bark-like layer at the surface of mesh fibers.[7]
Optical properties
PP can be made translucent when uncolored but is not as readily made transparent
as polystyrene, acrylic, or certain other plastics. It is often opaque or colored using pigments.
Industrial processes[edit]
Traditionally, three manufacturing processes are the most representative ways to produce
polypropylene.[16]
Hydrocarbon slurry or suspension: Uses a liquid inert hydrocarbon diluent in the reactor to
facilitate transfer of propylene to the catalyst, the removal of heat from the system, the
deactivation/removal of the catalyst as well as dissolving the atactic polymer. The range of
grades that could be produced was very limited. (The technology has fallen into disuse).
Bulk (or bulk slurry): Uses liquid propylene instead of liquid inert hydrocarbon diluent. The
polymer does not dissolve into a diluent, but rather rides on the liquid propylene. The formed
polymer is withdrawn and any unreacted monomer is flashed off.
Gas phase: Uses gaseous propylene in contact with the solid catalyst, resulting in a fluidizedbed medium.
Manufacturing
Melting process of polypropylene can be achieved via extrusion and molding. Common
extrusion methods include production of melt-blown and spun-bond fibers to form long rolls for
future conversion into a wide range of useful products, such as face masks, filters, diapers and
wipes.
The most common shaping technique is injection molding, which is used for parts such as cups,
cutlery, vials, caps, containers, housewares, and automotive parts such as batteries. The related
techniques of blow molding and injection-stretch blow molding are also used, which involve both
extrusion and molding.

The large number of end-use applications for polypropylene are often possible because of the
ability to tailor grades with specific molecular properties and additives during its manufacture.
For example, antistatic additives can be added to help polypropylene surfaces resist dust and
dirt. Many physical finishing techniques can also be used on polypropylene, such
as machining. Surface treatments can be applied to polypropylene parts in order to promote
adhesion of printing ink and paints.
Biaxially oriented polypropylene (BOPP)
When polypropylene film is extruded and stretched in both the machine direction and across
machine direction it is called biaxially oriented polypropylene. Biaxial orientation increases
strength and clarity.[17] BOPP is widely used as a packaging material for packaging products
such as snack foods, fresh produce and confectionery. It is easy to coat, print and laminate to
give the required appearance and properties for use as a packaging material. This process is
normally called converting. It is normally produced in large rolls which are slit on slitting
machines into smaller rolls for use on packaging machines.
Development trends[edit]
With the increase in the level of performance required for polypropylene quality in recent years,
a variety of ideas and contrivances have been integrated into the production process for
polypropylene.[18]
There are roughly two directions for the specific methods. One is improvement of uniformity of
the polymer particles produced using a circulation type reactor, and the other is improvement in
the uniformity among polymer particles produced by using a reactor with a narrow retention time
distribution.
Applications[edit]
As polypropylene is resistant to fatigue, most plastic living hinges, such as those on flip-top
bottles, are made from this material. However, it is important to ensure that chain molecules are
oriented across the hinge to maximise strength.
Very thin sheets (~220 m) of polypropylene are used as a dielectric within certain highperformance pulse and low-loss RF capacitors.
Polypropylene is used in the manufacturing piping systems; both ones concerned with highpurity and ones designed for strength and rigidity (e.g. those intended for use in potable
plumbing, hydronic heating and cooling, and reclaimed water).[19] This material is often chosen

for its resistance to corrosion and chemical leaching, its resilience against most forms of
physical damage, including impact and freezing, its environmental benefits, and its ability to be
joined by heat fusion rather than gluing.[20][21][22]
Many plastic items for medical or laboratory use can be made from polypropylene because it
can withstand the heat in an autoclave. Its heat resistance also enables it to be used as the
manufacturing material of consumer-grade kettles[citation needed]. Food containers made from it will
not melt in the dishwasher, and do not melt during industrial hot filling processes. For this
reason, most plastic tubs for dairy products are polypropylene sealed with aluminum foil (both
heat-resistant materials). After the product has cooled, the tubs are often given lids made of a
less heat-resistant material, such as LDPE or polystyrene. Such containers provide a good
hands-on example of the difference in modulus, since the rubbery (softer, more flexible) feeling
of LDPE with respect to polypropylene of the same thickness is readily apparent. Rugged,
translucent, reusable plastic containers made in a wide variety of shapes and sizes for
consumers from various companies such as Rubbermaid and Sterilite are commonly made of
polypropylene, although the lids are often made of somewhat more flexible LDPE so they can
snap on to the container to close it. Polypropylene can also be made into disposable bottles to
contain liquid, powdered, or similar consumer products, although HDPE and polyethylene
terephthalate are commonly also used to make bottles. Plastic pails, car batteries,
wastebaskets, pharmacy prescription bottles, cooler containers, dishes and pitchers are often
made of polypropylene or HDPE, both of which commonly have rather similar appearance, feel,
and properties at ambient temperature.
A common application for polypropylene is as biaxially oriented polypropylene (BOPP). These
BOPP sheets are used to make a wide variety of materials including clear bags. When
polypropylene is biaxially oriented, it becomes crystal clear and serves as an excellent
packaging material for artistic and retail products.
Polypropylene, highly colorfast, is widely used in manufacturing carpets, rugs and mats to be
used at home.[23]
Polypropylene is widely used in ropes, distinctive because they are light enough to float in
water.[24] For equal mass and construction, polypropylene rope is similar in strength to polyester
rope. Polypropylene costs less than most other synthetic fibers.
Polypropylene is also used as an alternative to polyvinyl chloride (PVC) as insulation for
electrical cables for LSZH cable in low-ventilation environments, primarily tunnels. This is
because it emits less smoke and no toxic halogens, which may lead to production of acid in
high-temperature conditions.

Polypropylene is also used in particular roofing membranes as the waterproofing top layer of
single-ply systems as opposed to modified-bit systems.
Polypropylene is most commonly used for plastic moldings, wherein it is injected into a mold
while molten, forming complex shapes at relatively low cost and high volume; examples include
bottle tops, bottles, and fittings.
It can also be produced in sheet form, widely used for the production of stationery folders,
packaging, and storage boxes. The wide color range, durability, low cost, and resistance to dirt
make it ideal as a protective cover for papers and other materials. It is used in Rubik's
Cube stickers because of these characteristics.
The availability of sheet polypropylene has provided an opportunity for the use of the material by
designers. The light-weight, durable, and colorful plastic makes an ideal medium for the creation
of light shades, and a number of designs have been developed using interlocking sections to
create elaborate designs.
Polypropylene sheets are a popular choice for trading card collectors; these come with pockets
(nine for standard-size cards) for the cards to be inserted and are used to protect their condition
and are meant to be stored in a binder.
Expanded polypropylene (EPP) is a foam form of polypropylene. EPP has very good impact
characteristics due to its low stiffness; this allows EPP to resume its shape after impacts. EPP is
extensively used in model aircraft and other radio controlled vehicles by hobbyists. This is
mainly due to its ability to absorb impacts, making this an ideal material for RC aircraft for
beginners and amateurs.
Polypropylene is used in the manufacture of loudspeaker drive units. Its use was pioneered by
engineers at the BBC and the patent rights subsequently purchased by Mission Electronics for
use in their Mission Freedom Loudspeaker and Mission 737 Renaissance loudspeaker.
Polypropylene fibres are used as a concrete additive to increase strength and reduce cracking
and spalling.[25] In the areas susceptible to earthquake, i.e., California, PP fibers are added with
soils to improve the soils strength and damping when constructing the foundation of structures
such as buildings, bridges, etc.[26]
Polypropylene is used in polypropylene drums.
In June 2016, a study showed that a mixture of polypropylene and
durable superoleophobic surfaces created by two engineers from Ohio State University can

repel liquids such as shampoo and oil. This technology could make it easier to remove all the
liquid contents from a polypropylene bottles, particularly those that have high surface tension
such as shampoo or oil.[27]
Clothing[edit]
Polypropylene is a major polymer used in nonwovens, with over 50% used[citation needed] for diapers
or sanitary products where it is treated to absorb water (hydrophilic) rather than naturally
repelling water (hydrophobic). Other interesting non-woven uses include filters for air, gas, and
liquids in which the fibers can be formed into sheets or webs that can be pleated to form
cartridges or layers that filter in various efficiencies in the 0.5 to 30 micrometre range. Such
applications occur in houses as water filters or in air-conditioning-type filters. The high surfacearea and naturally oleophilic polypropylene nonwovens are ideal absorbers of oil spills with the
familiar[citation needed] floating barriers near oil spills on rivers.
Polypropylene, or 'polypro', has been used for the fabrication of cold-weather base layers, such
as long-sleeve shirts or long underwear. Polypropylene is also used in warm-weather clothing,
in which it transports sweat away from the skin. More recently,[when?] polyester has replaced
polypropylene in these applications in the U.S. military, such as in the ECWCS.[28] Although
polypropylene clothes are not easily flammable, they can melt, which may result in severe burns
if the wearer is involved in an explosion or fire of any kind.[29] Polypropylene undergarments are
known for retaining body odors which are then difficult to remove. The current generation of
polyester does not have this disadvantage.[30]
Some fashion designers have adapted polypropylene to construct jewelry and other wearable
items.[citation needed]
Medical[edit]
Its most common medical use is in the synthetic, nonabsorbable suture Prolene, manufactured
by Ethicon Inc.
Polypropylene has been used in hernia and pelvic organ prolapse repair operations to protect
the body from new hernias in the same location. A small patch of the material is placed over the
spot of the hernia, below the skin, and is painless and rarely, if ever, rejected by the body.
However, a polypropylene mesh will erode the tissue surrounding it over the uncertain period
from days to years. Therefore, the FDA has issued several warnings on the use of
polypropylene mesh medical kits for certain applications in pelvic organ prolapse, specifically
when introduced in close proximity to the vaginal wall due to a continued increase in number of
mesh-driven tissue erosions reported by patients over the past few years.[31] Most recently, on 3

January 2012, the FDA ordered 35 manufacturers of these mesh products to study the side
effects of these devices.
Initially considered inert, polypropylene has been found to degrade while in the body. The
degraded material forms a bark-like shell on the mesh fibers and is prone to cracking.[7]
EPP model aircraft[edit]
Since 2001, expanded polypropylene (EPP) foams have been gaining in popularity and in
application as a structural material in hobbyist radio control model aircraft. Unlike expanded
polystyrene foam (EPS) which is friable and breaks easily on impact, EPP foam is able to
absorb kinetic impacts very well without breaking, retains its original shape, and exhibits
memory form characteristics which allow it to return to its original shape in a short amount of
time.[32] In consequence, a radio-control model whose wings and fuselage are constructed from
EPP foam is extremely resilient, and able to absorb impacts that would result in complete
destruction of models made from lighter traditional materials, such as balsa or even EPS foams.
EPP models, when covered with inexpensive fibreglass impregnated self-adhesive tapes, often
exhibit much increased mechanical strength, in conjunction with a lightness and surface finish
that rival those of models of the aforementioned types. EPP is also chemically highly inert,
permitting the use of a wide variety of different adhesives. EPP can be heat molded, and
surfaces can be easily finished with the use of cutting tools and abrasive papers. The principal
areas of model making in which EPP has found great acceptance are the fields of:

Wind-driven slope soarers

Indoor electric powered profile electric models

Hand launched gliders for small children

In the field of slope soaring, EPP has found greatest favour and use, as it permits the
construction of radio-controlled model gliders of great strength and maneuverability. In
consequence, the disciplines of slope combat (the active process of friendly competitors
attempting to knock each other's planes out of the air by direct contact) and slope pylon racing
have become commonplace, in direct consequence of the strength characteristics of the
material EPP.
Building construction[edit]
When the cathedral on Tenerife, La Laguna Cathedral, was repaired in 20022014, it turned out
that the vaults and dome were in a rather bad condition. Therefore, these parts of the building

were demolished, and replaced by constructions in polypropylene. This was reported as the first
time this material was used in this scale in buildings.[citation needed]
Rope[edit]
Under the trade name Ulstron polypropylene rope is used to manufacture scoop nets for
whitebait. It has also been used for sheets of yacht sails.[33][34]
Recycling[edit]

Polypropylene is recyclable and has the number "5" as its resin identification code:[35]
Repairing[edit]
Many objects are made with polypropylene precisely because it is resilient and resistant to most
solvents and glues. Also, there are very few glues available specifically for gluing PP. However,
solid PP objects not subject to undue flexing can be satisfactorily joined with a two part
epoxy glue or using hot-glue guns. Preparation is important and it is often helpful to roughen the
surface with a file, emery paper or other abrasive material to provide better anchorage for the
glue. Also it is recommended to clean with mineral spirits or similar alcohol prior to gluing to
remove any oils or other contamination. Some experimentation may be required. There are also
some industrial glues available for PP, but these can be difficult to find, especially in a retail
store.[citation needed]
PP can be melted using a speed welding technique. With speed welding, the plastic welder,
similar to a soldering iron in appearance and wattage, is fitted with a feed tube for the plastic
weld rod. The speed tip heats the rod and the substrate, while at the same time it presses the
molten weld rod into position. A bead of softened plastic is laid into the joint, and the parts and
weld rod fuse. With polypropylene, the melted welding rod must be "mixed" with the semimelted base material being fabricated or repaired. A speed tip "gun" is essentially a soldering
iron with a broad, flat tip that can be used to melt the weld joint and filler material to create a
bond.
Health concerns[edit]
The Environmental Working Group classifies PP as of low to moderate hazard.[36] PP is dopedyed, no water is used in its dyeing, in contrast with cotton.[37]

In 2008, researchers in Canada asserted that quaternary

ammonium biocides and oleamide were leaking out of certain polypropylene labware, affecting
experimental results.[38]As polypropylene is used in a wide number of food containers such as
those for yogurt, Health Canada media spokesman Paul Duchesne said the department will be
reviewing the findings to determine if steps are needed to protect consumers.[39]