PPSU
ASTM D6394 · ISO 1043 PPSU · also Radel R, Radel
PPSU (polyphenylsulfone, typified by Radel R) is an amorphous high-performance sulfone thermoplastic with a glass transition near 220 °C, a transparent amber appearance, very high notched impact toughness and excellent hydrolytic and steam stability; unfilled grades give 70 MPa tensile strength, 70% elongation and service to 180 °C.
PPSU grades and fills
PPSU is supplied in 3 conditions, soft to hard.
Compare all 3 grades and fillsHide
| Grade · open for datasheet | Best for | Yield MPa | Tensile MPa | Elong. % | Hardness |
|---|---|---|---|---|---|
Unfilled / Natural | Baseline transparent-amber grade for hot-water fittings, aircraft interior parts and tough housings where no filler or medical certification is needed. | 70 | 70 | 90 | 87 Shore D |
20 % glass-fiber reinforced | Pick when stiffness, creep resistance and dimensional stability matter more than impact toughness or transparency. | 110 | 3 | ||
30 % glass-fiber reinforced | Highest stiffness and lowest thermal expansion PPSU grade for structural brackets and hot-fluid manifolds; brittle relative to unfilled PPSU and abrasive to tooling. | 130 | 2.5 |
Supply forms, finishes and certifications
Ways PPSU is supplied — form, process route, surface or paperwork — without a datasheet of their own. The property values above apply.
| Option | What it is | Type |
|---|---|---|
EXT | Extruded Stock Shape | Supply form |
FDA | FDA / Food-Contact & Potable-Water Grade | Certification |
Medical GradeDefault | Unfilled, biocompatible / sterilizable | Certification |
What is PPSU?
PPSU (polyphenylsulfone, typified by Radel R) is an amorphous high-performance sulfone thermoplastic with a glass transition near 220 °C, a transparent amber appearance, very high notched impact toughness and excellent hydrolytic and steam stability; unfilled grades give 70 MPa tensile strength, 70% elongation and service to 180 °C. It survives over a thousand steam-autoclave cycles and resists hospital disinfectants and alkalis, so it is specified for sterilisation trays, surgical instrument handles, baby bottles, aircraft interior parts and hot-water fittings in sheet, rod and moulded form. Limits are high cost, poor UV resistance with yellowing in sunlight, stress cracking in ketones, chlorinated hydrocarbons and esters, and 360–390 °C processing that demands thorough drying. PPSU has a density of 1.29 g/cm³ (0.0466 lb/in³), heavier than 68% of polymer grades. Its glass-transition temperature is 220°C (428 °F). PPSU has a yield strength of 70 MPa (10.2 ksi) and a tensile strength of 70 MPa (10.2 ksi) — stronger than 79% of polymer grades. Elongation at break is 80% and the elastic modulus is 2.3 GPa (0.339 Msi).
What is PPSU used for?
- Medical sterilisation trays and cases
- Surgical instrument handles
- Sterilizer components
- Baby bottles and food-contact hardware
- Aircraft interior parts
- Hot-water plumbing fittings and manifolds
- Dental instrument components
Advantages
- Conducts heat well — 0.35 W/m·K (0.202 BTU/hr·ft·°F), better than 91% of polymer grades
- High service temperature — 180°C (356 °F), better than 85% of polymer grades
- Good corrosion resistance — 90/100, better than 82% of polymer grades
- High strength — 70 MPa (10.2 ksi), better than 79% of polymer grades
- Polishes to a fine finish — 70/100, better than 77% of polymer grades
Limitations
- High embodied carbon — 8.5 kg CO₂/kg, worse than 85% of polymer grades
PPSU properties
Typical room-temperature values in the Medical Grade condition; bars are the position among polymer grades.
Physical5
PPSU has a density of 1.29 g/cm³ (0.0466 lb/in³), heavier than 68% of polymer grades. Its glass-transition temperature is 220°C (428 °F).
Mechanical16
PPSU has a yield strength of 70 MPa (10.2 ksi) and a tensile strength of 70 MPa (10.2 ksi) — stronger than 79% of polymer grades. Elongation at break is 80% and the elastic modulus is 2.3 GPa (0.339 Msi).
Thermal11
PPSU is rated for continuous service to 180°C (356 °F). It conducts heat at 0.35 W/m·K (0.202 BTU/hr·ft·°F), better than 91% of polymer grades. Thermal expansion is 55 µm/m·K (30.6 µin/in·°F).
Electrical7
PPSU is an electrical insulator with a dielectric strength of 15 kV/mm (381 V/mil) and a resistivity of 1×10¹⁴ Ω·m.
Chemical & Environmental3
Corrosion resistance is excellent (90/100), better than 82% of polymer grades. UV resistance is poor.
Sustainability4
Producing a kilogram of PPSU takes about 145 MJ of energy and emits 8.5 kg of CO₂ — more than 83% of polymer grades. Typical recycled content is 0%.
Manufacturability8
PPSU's machinability is good (62/100, better than 60% of polymer grades); weldability very good (70/100); formability good (55/100).
Common Calculations5
Values are nominal handbook figures for design screening. Certified mill or lot data ships with every FabDigit order on request.
Strength versus weight in the polymer family
Yield strength against density for every polymer grade FabDigit runs. PPSU is highlighted; hover a dot for its name, or open the interactive family chart.
Working with PPSU
Is PPSU easy to machine?
Machines like a tough amorphous thermoplastic — sharp positive-rake carbide tools, high speed, moderate feed and generous air or water-soluble coolant; avoid petroleum-based cutting oils and anneal (≈160 °C) before finishing to prevent stress cracking.
Can PPSU be welded?
Joins well by ultrasonic, hot-plate, IR and vibration welding, plus solvent bonding with cyclohexanone-type systems; not fusion-weldable by metal-style methods and adhesive joints need plasma or abrasive surface prep.
Can PPSU be formed, bent or molded?
Dry 3–4 h at 135–150 °C to <0.05 % moisture, mold at 355–390 °C melt with 135–165 °C tools; thermoforming and extrusion are practical above Tg, and thick sections should be annealed to relieve molded-in stress.
Manufacturability
The process limits FabDigit's quote engine applies to PPSU. Design inside these and the part quotes instantly; outside them it routes to an engineer.
CNC machining
| Machinability | Better62 / 100 |
|---|---|
| ISO material group | N.8 |
| Cutting speed (rough / finish) | 400 / 500 m/min |
| Minimum wall | 0.5 mm |
| Minimum internal radius | 1 mm |
| Drill depth limit | 10× diameter |
| Best surface (machined / polished) | Ra 0.8 / — |
| Hardenable after machining | No |
Sheet metal
| Formability | Good55 / 100 |
|---|---|
| Weldability | Better70 / 100 |
Injection molding
| Mold shrinkage | — |
|---|---|
| Wall thickness | — – — |
| Recommended draft | — |
| Pre-drying | — |
PPSU chemical composition (wt %)
Limits by weight percent from the governing specification, written the way the spec states them — a single maximum for impurities, a range for alloying elements, and the base element as balance. Nominal is the typical mid-range value.
| Element | Spec limit (wt %) | Nominal |
|---|---|---|
| glass fiberOnly in GF20 / GF30 reinforced variants | 0 – 30 | 0 |
| pigment / additive packageColorants, mold release; medical grades are formulated for ISO 10993 compliance | 0 – 2 | 0.5 |
| polyphenylsulfone repeat unit (bisphenolAmorphous polyaryl ether sulfone; no halogen or added flame retardant in natural grade | balance |
What surface finishes work on PPSU?
Takes fine polishing to a transparent amber finish, accepts pad printing and laser marking; paint or metallize only after plasma/flame treatment, and expect yellowing without a UV-stabilized topcoat.
Surface treatments FabDigit runs on polymer parts — pick them in the quote configurator or call them out on the drawing. Each links to its datasheet in the surface-finish library (thickness, specs, call-out, material verdicts).
Injection Molding Coating
Organic Coating
Metallization / Functional
Equivalent designations
Standards and trade names that resolve to PPSU in FabDigit's catalog. Equivalence is nominal — check the exact specification when certification matters.
- ASTM
- D6394
- ISO
- 1043 PPSU
- Trade names
- Radel RRadelUltrason P
- Also called
- Polyphenylsulfone
How much does PPSU cost?
PPSU is a specialty-cost polymer ($$$$$), pricier than about 99% of the materials FabDigit quotes. Part price depends far more on geometry, tolerance and quantity than on the raw stock — upload a CAD file for a live quote.
PPSU — frequently asked
What is PPSU used for?
PPSU is typically used for medical sterilisation trays and cases, surgical instrument handles, sterilizer components, baby bottles and food-contact hardware, aircraft interior parts and hot-water plumbing fittings and manifolds. In short: durable chemical resistant.
What is the yield strength of PPSU?
PPSU has a typical yield strength of 70 MPa (10.2 ksi) and a tensile strength of 70 MPa (10.2 ksi) — stronger than 79% of polymer grades. Strength varies by condition: see the 3 listed tempers.
Is PPSU easy to machine?
Reasonably — machinability is rated good (62/100, better than 60% of polymer grades). Machines like a tough amorphous thermoplastic — sharp positive-rake carbide tools, high speed, moderate feed and generous air or water-soluble coolant; avoid petroleum-based cutting oils and anneal (≈160 °C) before finishing to prevent stress cracking.
Can PPSU be welded?
Yes — weldability is rated very good (70/100). Joins well by ultrasonic, hot-plate, IR and vibration welding, plus solvent bonding with cyclohexanone-type systems; not fusion-weldable by metal-style methods and adhesive joints need plasma or abrasive surface prep.
What surface finishes work on PPSU?
Takes fine polishing to a transparent amber finish, accepts pad printing and laser marking; paint or metallize only after plasma/flame treatment, and expect yellowing without a UV-stabilized topcoat.
Can PPSU be formed, bent or molded?
Dry 3–4 h at 135–150 °C to <0.05 % moisture, mold at 355–390 °C melt with 135–165 °C tools; thermoforming and extrusion are practical above Tg, and thick sections should be annealed to relieve molded-in stress.
What is the maximum service temperature of PPSU?
PPSU is rated for continuous use to about 180°C (356 °F), and briefly to 220°C. Strength falls off well before that limit — check the elevated-temperature data for load-bearing parts.
How much does PPSU cost?
PPSU is a specialty-cost polymer ($$$$$), pricier than about 99% of the materials FabDigit quotes. Part price depends far more on geometry, tolerance and quantity than on the raw stock — upload a CAD file for a live quote.
Can FabDigit make parts in PPSU?
Yes — PPSU is available for CNC machining, sheet metal and injection molding with instant online pricing. Upload a STEP file to get a price and a DFM check.
Sources
- Radel R PPSU Resin — Design and Processing Guide — Solvay Specialty Polymers (2023)
- Ultrason P (PPSU) Product Brochure — BASF (2022)
- TECASON P natural — PPSU stock shapes — Ensinger (2023)
- CAMPUS Plastics — PPSU material records — CWFG / CAMPUS consortium (2024)
- ASTM D6394 Standard Specification for Sulfone Plastics (SP) Materials — ASTM International (2022)
- ISO 10993-1 Biological evaluation of medical devices — ISO (2018)
- Handbook of Plastics, Elastomers and Composites — sulfone polymers chapter — McGraw-Hill (2006)
Property data is compiled from published supplier and standards handbooks and normalised for comparison; hardness values on non-Brinell scales are converted approximately for charting only. Manufacturability limits are FabDigit quote-engine defaults and may be relaxed by engineering review. Nothing on this page is a certification — request mill certs, CoC or material test reports with your order.