Polymers — Types & Categories (AQA GCSE Design & Technology): Revision Note
Exam code: 8552
Thermoforming polymers
What are thermoforming polymers?
Thermoforming polymers soften when heated, harden when cooled, and can be reheated
Suitable for recycling
Uses: mass-produced packaging and everyday applications
Polymer | Key Properties | Common Uses |
|---|---|---|
Acrylic (PMMA) | Often clear (glass-like), rigid, weather-resistant, cracks on impact | Signs, displays, windows, outdoor screens |
High Impact Polystyrene (HIPS) | Tougher than standard polystyrene, lightweight, easily shaped | Vacuum forming, model-making, fridge lining |
HDPE | Tough, durable, good chemical/water resistance, slightly flexible | Buckets, bins, plastic piping |
Polypropylene (PP) | Tough, flexible, heat-resistant, fatigue-resistant, ideal for "living hinge" | Food containers, hinges, medical applications |
PVC | Very flexible or very rigid options, excellent chemical resistance, weather-resistant | Pipes, guttering, electrical cable insulation, window frames |
PET | Often clear/translucent, lightweight, good gas/moisture barrier, food-safe, recyclable | Drinking bottles, food packaging |
Thermoset polymers
What are thermoset polymers?
Thermoset polymers set permanently once heated and cannot be remelted or reshaped
Harder and more rigid than thermoforming polymers
Non-recyclable
Polymer | Key Properties | Common Uses |
|---|---|---|
Epoxy resin (ER) | Very strong, durable, good chemical/heat resistance, excellent adhesive | Adhesive, worktop coating, GRP, CRP |
Melamine-formaldehyde (MF) | Very hard, heat-resistant, good scratch resistance, smooth surface | Kitchen worktops (laminate), tableware |
Phenol-formaldehyde (PF) | Very heat-resistant, good electrical insulator, very strong and rigid | Cooking pan handles, circuit boards, electrical plugs |
Polyester resin (PR) | Very hard and rigid, excellent chemical resistance, mixed with fibres for strength | GRP, CRP, boat hulls, car body panels |
Urea-formaldehyde (UF) | Very hard and rigid, effective electrical insulator, very smooth finish | Plug sockets, plugs, worktop laminates |
Examiner Tips and Tricks
The key distinction between thermoforming and thermoset polymers is reversibility. Thermoforming polymers can be reheated and reshaped (making them recyclable), while thermoset polymers set permanently and cannot be recycled.
Exam questions often ask you to justify a polymer choice for a specific product — always link the polymer’s properties to the product requirements.
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