The use of polycarbonate containers for the purpose of food storage is controversial. The basis of this controversy is their hydrolysis (degradation by water, often referred to as leaching) occurring at high temperature, releases bisphenol A:

Polycarbonate is commonly used in eye protection, as well as in other projectile-resistant viewing and lighting applications that would normally indicate the use of glass, but require much higher impact-resistance. Polycarbonate lenses also protect the eye from UV light. Many kinds of lenses are manufactured from polycarbonate, including automotive headlamp lenses, lighting lenses, sunglass/eyeglass lenses, camera lenses, swimming goggles and SCUBA masks, and safety glasses/goggles/visors including visors in sporting helmets/masks and police riot gear (helmet visors, riot shields, etc.). Windscreens in small motorized vehicles are commonly made of polycarbonate, such as for motorcycles, ATVs, golf carts, and small airplanes and helicopters.

While there are several reliable injection molding suppliers and medical injection molding companies to choose from, we have assembled a list of the best of them to help you make the best decision.

In addition to various recognized certifications and over 10 years of experience in precision mold making and cleanroom injection moulding, Seasky Medical partners with trusted raw material companies to ensure all injection molding medical devices or other precise parts

Husky provides clients with injection molding systems, hot runners, controllers, and auxiliaries that use less energy and material, with reduced CO2 emissions.

Polycarbonate is a durable material. Although it has high impact-resistance, it has low scratch-resistance. Therefore, a hard coating is applied to polycarbonate eyewear lenses and polycarbonate exterior automotive components. The characteristics of polycarbonate compare to those of polymethyl methacrylate (PMMA, acrylic), but polycarbonate is stronger and will hold up longer to extreme temperature. Thermally processed material is usually totally amorphous,[7] and as a result is highly transparent to visible light, with better light transmission than many kinds of glass.

Carbonate esters have planar OC(OC)2 cores, which confer rigidity. The unique O=C bond is short (1.173 Å in the depicted example), while the C-O bonds are more ether-like (the bond distances of 1.326 Å for the example depicted). Polycarbonates received their name because they are polymers containing carbonate groups (−O−(C=O)−O−). A balance of useful features, including temperature resistance, impact resistance and optical properties, positions polycarbonates between commodity plastics and engineering plastics.

Polycarbonate has a glass transition temperature of about 147 °C (297 °F),[8] so it softens gradually above this point and flows above about 155 °C (311 °F).[9] Tools must be held at high temperatures, generally above 80 °C (176 °F) to make strain-free and stress-free products. Low molecular mass grades are easier to mold than higher grades, but their strength is lower as a result. The toughest grades have the highest molecular mass, but are more difficult to process.

Sumimoto combines tradition, and innovation from Germany and Japan to create advanced injection moulding technology, from small and mid-sized molding machines to custom plastic solutions for clients around the globe.

A major polycarbonate market is the production of compact discs, DVDs, and Blu-ray discs.[13] These discs are produced by injection-molding polycarbonate into a mold cavity that has on one side a metal stamper containing a negative image of the disc data, while the other mold side is a mirrored surface. Typical products of sheet/film production include applications in advertisement (signs, displays, poster protection).[6]

KraussMaffei is one of the global leaders in the production of injection molding, extrusion, and reaction processing machinery. They offer plastic molding solutions for various industries and technologies, including automotive, medical technology, beverage packaging, compound and recycling, and much more.

Husky technologies is a world leader in the production of injection molding systems for medical devices, consumer goods, beverages, and automotive products. They provide end-to-end business solutions to ensure products are delivered, installed, and set up to the customer’s exact specifications.

Phenol derivatives are environmental pollutants, classified as volatile organic compounds (VOC). Studies show they are likely to facilitate ground level ozone formation and increase photo-chemical smog.[42] In aquatic bodies, they can potentially accumulate in organisms. They are persistent in landfills, do not readily evaporate and would remain in the atmosphere.[43]

Photo-aging is another degradation route for polycarbonates. Polycarbonate molecules (such as the aromatic ring) absorb UV radiation. This absorbed energy causes cleavage of covalent bonds which initiates the photo-aging process. The reaction can be propagated via side chain oxidation, ring oxidation or photo-Fries rearrangement. Products formed include phenyl salicylate, dihydroxybenzophenone groups, and hydroxydiphenyl ether groups.[37][39][40]

Seasky Medical serves you with medical injection molding solutions from design to tooling to material selection and manufacturing. Contact our specialized team and solve your problem now.

In the presence of UV light, oxidation of this polymer yields compounds such as ketones, phenols, o-phenoxybenzoic acid, benzyl alcohol and other unsaturated compounds. This has been suggested through kinetic and spectral studies. The yellow color formed after long exposure to sun can also be related to further oxidation of phenolic end group[37]

Seasky Medical serves you with medical injection molding solutions from design to tooling to material selection and manufacturing. Contact our specialized team and solve your problem now.

The first step of the synthesis involves treatment of bisphenol A with sodium hydroxide, which deprotonates the hydroxyl groups of the bisphenol A.[6]

In the automotive industry, injection-molded polycarbonate can produce very smooth surfaces that make it well-suited for sputter deposition or evaporation deposition of aluminium without the need for a base-coat. Decorative bezels and optical reflectors are commonly made of polycarbonate. Its low weight and high impact resistance have made polycarbonate the dominant material for automotive headlamp lenses. However, automotive headlamps require outer surface coatings because of its low scratch resistance and susceptibility to ultraviolet degradation (yellowing). The use of polycarbonate in automotive applications is limited to low stress applications. Stress from fasteners, plastic welding and molding render polycarbonate susceptible to stress corrosion cracking when it comes in contact with certain accelerants such as salt water and plastisol. It can be laminated to make bullet-proof "glass", although "bullet-resistant" is more accurate for the thinner windows, such as are used in bullet-resistant windows in automobiles. The thicker barriers of transparent plastic used in teller's windows and barriers in banks are also polycarbonate.

Choosing one out of the many injection molding suppliers may not be easy as you have to consider various factors, such as quality, price, and shipping time. However, in this post, we have streamlined your options by listing the top injection molding suppliers in the world.

Polycarbonate is also used as a printing substrate for nameplate and other forms of industrial grade under printed products. The polycarbonate provides a barrier to wear, the elements, and fading.

Polycarbonate is mainly used for electronic applications that capitalize on its collective safety features. A good electrical insulator with heat-resistant and flame-retardant properties, it is used in products associated with power systems and telecommunications hardware. It can serve as a dielectric in high-stability capacitors.[6] Commercial manufacture of polycarbonate capacitors mostly stopped after sole manufacturer Bayer AG stopped making capacitor-grade polycarbonate film at the end of 2000.[11][12]

The leaching of BPA from polycarbonate can also occur at environmental temperature and normal pH (in landfills).The amount of leaching increases as the polycarbonate parts get older. A study found that the decomposition of BPA in landfills (under anaerobic conditions) will not occur.[35] It will therefore be persistent in landfills. Eventually, it will find its way into water bodies and contribute to aquatic pollution.[35][36]

In this way, approximately one billion kilograms of polycarbonate is produced annually. Many other diols have been tested in place of bisphenol A, e.g. 1,1-bis(4-hydroxyphenyl)cyclohexane and dihydroxybenzophenone. The cyclohexane is used as a comonomer to suppress crystallisation tendency of the BPA-derived product. Tetrabromobisphenol A is used to enhance fire resistance. Tetramethylcyclobutanediol has been developed as a replacement for BPA.[6]

Seasky Medical is an experienced injection molding manufacturer that puts quality first and provides customers with a cost-effective and hassle-free way of purchasing injection molding solutions. You can contact us for your plastic molding supplies business.

More than 100 studies have explored the bioactivity of bisphenol A derived from polycarbonates. Bisphenol A appeared to be released from polycarbonate animal cages into water at room temperature and it may have been responsible for enlargement of the reproductive organs of female mice.[30] However, the animal cages used in the research were fabricated from industrial grade polycarbonate, rather than FDA food grade polycarbonate.

Many polycarbonate grades are used in medical applications and comply with both ISO 10993-1 and USP Class VI standards (occasionally referred to as PC-ISO). Class VI is the most stringent of the six USP ratings. These grades can be sterilized using steam at 120 °C, gamma radiation, or by the ethylene oxide (EtO) method.[20] Trinseo strictly limits all its plastics with regard to medical applications.[21][22] Aliphatic polycarbonates have been developed with improved biocompatibility and degradability for nanomedicine applications.[23]

Chen Hsong is one of the largest manufacturers of injection molding machines in the world, producing over 20,000 machines each year and supplying to more than 90 countries worldwide, including China, U.S.A., Germany, Turkey, Canada, France, U.K., Brazil, Argentina, and Mexico, among others.

Arburg is an application-oriented and efficient plastic injection mold supplier. This company uses a wide range of processes to manufacture plastic parts and injection molding machines that are specific to your industry and tailored to your requirements.

The second largest consumer of polycarbonates is the construction industry, e.g. for domelights, flat or curved glazing, roofing sheets and sound walls. Polycarbonates are used to create materials used in buildings that must be durable but light.

Engel is a top plastic injection molding supplier that specializes in the development and production of injection moulding machines, technologies, and digital solutions. To shape the plastic processes of the future, this company provides injection moulding solutions and plastic molding supplies to the electronic, medical, automotive, and packaging industries.

The main polycarbonate material is produced by the reaction of bisphenol A (BPA) and phosgene COCl2. The overall reaction can be written as follows:

Studies have shown that at temperatures above 70 °C, and high humidity, polycarbonate will hydrolyze to bisphenol A (BPA). After about 30 days at 85 °C/96% RH, surface crystals are formed which for 70% consisted of BPA.[34] BPA is a compound that is currently on the list of potential environmental hazardous chemicals. It is on the watch list of many countries, such as United States and Germany.[35]

KraussMaffei manufactures across 16 locations on the globe, including China and the USA, and ensures sustainable added value to customers across these locations by delivering standardized products, and digital and service solutions.

In 2001 a species of fungus in Belize, Geotrichum candidum, was found to consume the polycarbonate found in compact discs (CD).[44] This has prospects for bioremediation. However, this effect has not been reproduced.

Plastek Group complies with various quality management & good manufacturing practices and conforms to applicable regulatory requirements that guarantee the reliability and efficiency of their packages and machines.

Haitian International is one of the leading plastic molding suppliers worldwide. For over five decades, this company has manufactured and supplied plastic injection molding machines with competitive advantages to clients in America, Asia, Europe, Australia, and Africa.

Haitian International provides high-end and standard injection molding solutions through their subsidiaries: Zhafir Plastics Machinery and Haitian Plastics Machinery. Working with a product portfolio that covers a wide range of molding machines and plastic solutions, they can meet customers’ demands for bulk and high-precision products.

Sumitomo (SHI) Demag is a product of the merger between Demag Plastics Group and the Plastics Machinery Division of Sumitomo Heavy Industries, Ltd. Proven by facts and figures and customer testimonials, injection moulding cells from this company delivers the most energy-efficient and precise products.

Polycarbonates are used extensively in 3D FDM printing, producing durable strong plastic products with a high melting point. Polycarbonate is relatively difficult for casual hobbyists to print compared to thermoplastics such as Polylactic acid (PLA) or Acrylonitrile butadiene styrene (ABS) because of the high melting point, difficulty with print bed adhesion, tendency to warp during printing, and tendency to absorb moisture in humid environments. Despite these issues, 3D printing using polycarbonates is common in the professional community.

The cockpit canopy of the Lockheed Martin F-22 Raptor jet fighter is fabricated from high optical quality polycarbonate. It is the largest item of its type.[14][15]

The diphenoxide (Na2(OC6H4)2CMe2) reacts with phosgene to give a chloroformate, which subsequently is attacked by another phenoxide. The net reaction from the diphenoxide is:

The light weight of polycarbonate as opposed to glass has led to development of electronic display screens that replace glass with polycarbonate, for use in mobile and portable devices. Such displays include newer e-ink and some LCD screens, though CRT, plasma screen and other LCD technologies generally still require glass for its higher melting temperature and its ability to be etched in finer detail.

Some smartphone manufacturers use polycarbonate. Nokia used polycarbonate in their phones starting with the N9's unibody case in 2011. This practice continued with various phones in the Lumia series. Samsung started using polycarbonate with Galaxy S III's hyperglaze-branded removable battery cover in 2012. This practice continues with various phones in the Galaxy series. Apple started using polycarbonate with the iPhone 5C's unibody case in 2013.

As a medical plastics manufacturer, Engel offers a full range of precise solutions and easy-to-use digital options that optimize their products’ life cycle and ensure proper implementation of product requirements.

Through the pursuit of technological advancements, first-class quality, and manufacturing innovations, Chen Hsong secures its leading position in this industry.

Unlike most thermoplastics, polycarbonate can undergo large plastic deformations without cracking or breaking. As a result, it can be processed and formed at room temperature using sheet metal techniques, such as bending on a brake. Even for sharp angle bends with a tight radius, heating may not be necessary. This makes it valuable in prototyping applications where transparent or electrically non-conductive parts are needed, which cannot be made from sheet metal. PMMA/Acrylic, which is similar in appearance to polycarbonate, is brittle and cannot be bent at room temperature.

Below is a list of the top injection molding suppliers in the world. We will highlight their business information, certifications, and products & services they offer, as well as give reasons why they are the top choices.

Milacron is a leading injection mold supplier with a full product portfolio, covering injection molding, extrusion machines, and auxiliary equipment. To maintain this leading position and strong market presence, they provide highly customized equipment, components, and service that meet customers’ needs.

Polycarbonates were first discovered in 1898 by Alfred Einhorn, a German scientist working at the University of Munich.[25] However, after 30 years' laboratory research, this class of materials was abandoned without commercialization. Research resumed in 1953, when Hermann Schnell at Bayer in Uerdingen, Germany patented the first linear polycarbonate. The brand name "Makrolon" was registered in 1955.[26]

As a world-class plastic mold supplier, Plastek Group has manufacturing sites in the US, UK, Brazil, and Mexico. Operating from facilities that are well-equipped with a variety of technology, machinery, knowledge, talent, and skill, this group ensures that the best plastic packaging and custom plastic molding needs are manufactured and supplied.

Sodium hypochlorite bleach and other alkali cleaners catalyze the release of the bisphenol A from polycarbonate containers.[32][33] Polycarbonate is incompatible with ammonia and acetone. Alcohol is a recommended organic solvent for cleaning grease and oils from polycarbonate.

Seasky Medical is an injection mold supplier that offers plastic molding solutions for various industries and technologies, including medical filed, electronic housing, automotive and others. By carrying out the production, assembly, and packaging of products in an ISO 8 cleanroom using reliable, cutting-edge equipment, they ensure all molding solutions meet international quality and industry standards.

Waste polycarbonate will degrade at high temperatures to form solid, liquid and gaseous pollutants. A study showed that the products were about 40–50 wt.% liquid, 14–16 wt.% gases, while 34–43 wt.% remained as solid residue. Liquid products contained mainly phenol derivatives (~75wt.%) and bisphenol (~10wt.%) also present.[39] Polycarbonate, however, can be safely used as a carbon source in the steel-making industry.[41]

Patent priority was resolved in Bayer's favor, and Bayer began commercial production under the trade name Makrolon in 1958. GE began production under the name Lexan in 1960, creating the GE Plastics division in 1973.[29]

Also in 1953, and one week after the invention at Bayer, Daniel Fox at General Electric (GE) in Pittsfield, Massachusetts, independently synthesized a branched polycarbonate. Both companies filed for U.S. patents in 1955, and agreed that the company lacking priority would be granted a license to the technology.[27][28]

Polycarbonates (PC) are a group of thermoplastic polymers containing carbonate groups in their chemical structures. Polycarbonates used in engineering are strong, tough materials, and some grades are optically transparent. They are easily worked, molded, and thermoformed. Because of these properties, polycarbonates find many applications. Polycarbonates do not have a unique resin identification code (RIC) and are identified as "Other", 7 on the RIC list. Products made from polycarbonate can contain the precursor monomer bisphenol A (BPA).

Other miscellaneous items include durable, lightweight luggage, MP3/digital audio player cases, ocarinas, computer cases, riot shields, instrument panels, tealight candle containers and food blender jars. Many toys and hobby items are made from polycarbonate parts, like fins, gyro mounts, and flybar locks in radio-controlled helicopters,[18] and transparent LEGO (ABS is used for opaque pieces).[19]

Plastic injection molded products now play an important role in many industries, including medicine, automation, and packaging, among others. Hence, it is critical to ensure the high quality of products and their components throughout the manufacturing process.

As more and more governments are restricting the use of glass in pubs and clubs due to the increased incidence of glassings, polycarbonate glasses are becoming popular for serving alcohol because of their strength, durability, and glass-like feel.[16][17]

Polycarbonate, being a versatile material with attractive processing and physical properties, has attracted myriad smaller applications. The use of injection molded drinking bottles, glasses and food containers is common, but the use of BPA in the manufacture of polycarbonate has stirred concerns (see Potential hazards in food contact applications), leading to development and use of "BPA-free" plastics in various formulations.

This product can be further oxidized to form smaller unsaturated compounds. This can proceed via two different pathways, the products formed depends on which mechanism takes place.[38]

Standard polycarbonate resins are not suitable for long term exposure to UV radiation. To overcome this, the primary resin can have UV stabilisers added. These grades are sold as UV stabilized polycarbonate to injection moulding and extrusion companies. Other applications, including polycarbonate sheets, may have the anti-UV layer added as a special coating or a coextrusion for enhanced weathering resistance.

An analysis of the literature on bisphenol A leachate low-dose effects by vom Saal and Hughes published in August 2005 seems to have found a suggestive correlation between the source of funding and the conclusion drawn. Industry-funded studies tend to find no significant effects whereas government-funded studies tend to find significant effects.[31]

Benefits over glass and metal back covers include durability against shattering (advantage over glass), bending and scratching (advantage over metal), shock absorption, low manufacturing costs, and no interference with radio signals and wireless charging (advantage over metal).[24] Polycarbonate back covers are available in glossy or matte surface textures.[24]

Having adequate expertise, advanced plastics processing technology, and a committed team, Milacron provides its over 27,000 customers with a one-stop shop for all plastic molding solutions and guarantees the best the industry has to offer.

So-called "theft-proof" large plastic packaging for smaller items, which cannot be opened by hand, is typically made from polycarbonate.

Injection moulded parts, made by injecting molten material into a mold, make up a large section of the entire plastic processing industry. As a result of its manufacturing capacity, accuracy, speed, and ability to create complex designs, this manufacturing process has become popular among producers.

Arburg is one of the most established plastic molding companies, with 33 locations across the world and its largest production factory in Loßburg, Germany.