PPSU Radel: Properties, Uses & Cost Guide
Tensile data verified against MatWeb.com database & manufacturer datasheets · Last updated July 2026
Published: 2026-05-28
Polyphenylsulfone (PPSU), commercially known as Solvay Radel, is the highest-performing member of the sulfone polymer family—offering the best combination of impact resistance, chemical resistance, and sterilization tolerance of any transparent...
Polyphenylsulfone (PPSU), commercially known as Solvay Radel, is the highest-performing member of the sulfone polymer family—offering the best combination of impact resistance, chemical resistance, and sterilization tolerance of any transparent thermoplastic. Its notched Izod impact strength of 690 J/m (unnotched: no break) is the highest of any amorphous thermoplastic, approximately 10× higher than standard PSU and competitive with polycarbonate—but unlike polycarbonate, PPSU retains this toughness after 1000+ autoclave cycles and resists stress cracking in the presence of aggressive disinfectants and cleaning agents.
PPSU is the material of choice for aircraft interior components (FAR 25.853 compliant for low heat release and low smoke density—OSU heat release <65 kW/m²), reusable medical devices subjected to aggressive chemical sterilization (hydrogen peroxide plasma, peracetic acid), and infant formula bottles/childcare products where the combination of clarity, toughness, and BPA-free chemistry is valued. PPSU has the highest chemical resistance in the sulfone family—it withstands repeated exposure to Skydrol hydraulic fluid, jet fuel, and common hospital disinfectants (CaviCide, Virex) that cause rapid stress cracking in polycarbonate and standard PSU. Processing requires melt temperatures of 350-390°C and mold temperatures of 120-160°C.
Recommended Applications
PPSU Radel is commonly specified for:
⚠ Not Recommended For
PPSU Radel is not recommended for:
- Applications requiring high elongation or ductility (PPS elongation <1% — very brittle at room temperature)
- Strong oxidizing acid environments at elevated temperature (fuming nitric acid, concentrated sulfuric above 150°C)
- Welded or bonded assemblies (PPS has poor weldability — use mechanical fasteners)
Selection & Application Guide
PPS is the cost-performance leader among high-temperature semicrystalline polymers, offering 200-240°C continuous service temperature, exceptional chemical resistance, and inherent flame retardancy at $15-40/kg — a fraction of PEEK's cost. Choose PPS over PEEK when temperatures stay below 200°C and the application prioritizes chemical resistance and dimensional stability over mechanical toughness. PPS's low elongation (1-3%) and brittleness limit its use in impact-loaded applications.
Real-World Applications
PPS withstands under-hood temperatures, fuel, oil, and coolant exposure while maintaining dimensional stability for precision sensor housings and fuel system components.
PPS's high dielectric strength, CTI rating, and UL94 V-0 flammability make it standard for high-temperature electrical connectors in automotive and industrial equipment.
Glass-filled PPS (40% GF) provides the chemical resistance, stiffness, and temperature capability needed for pump impellers handling hot, corrosive fluids.
PPS's low moisture absorption, chemical resistance to hydraulic fluids, and dimensional stability make it suitable for precision valve bodies and spools.
Processing & Cost Considerations
Manufacturing Tips
- PPS processes at 300-330°C melt temperature with mold temperatures of 130-150°C. These temperatures are achievable on most standard injection molding machines with high-temperature capability — no special equipment needed like PEEK.
- PPS is highly crystalline and crystallizes rapidly during molding. Mold temperature above 130°C ensures adequate crystallinity (>50%) for optimal chemical resistance and dimensional stability. Lower mold temperatures produce lower crystallinity with reduced chemical resistance.
- PPS is extremely fluid when molten — it will flash through very small gaps. Molds must have precise parting line fits, and injection pressures should be carefully controlled to prevent flash. Use of low-pressure holding phase is recommended.
PPS is the most affordable high-temperature polymer at $15-40/kg (40% glass-filled grade: $20-30/kg). It costs 4-8× less than PEEK while offering similar chemical resistance and only slightly lower temperature capability. PPS's excellent flow characteristics also reduce molding cycle times and energy costs. The total system cost often favors PPS over metals or more expensive polymers in automotive and chemical processing applications.
Technical Properties
| Density | 1.29 g/cm³ |
|---|---|
| Tensile Strength | 76 MPa |
| Melting Point | N/A (Amorphous, Tg 220°C) |
| Shrinkage Rate | 0.6-0.7% |
| Flexural Modulus | 2.4 GPa |
| Hdt | 207 °C at 1.82 MPa |
| Continuous Service Temp | 180 °C |
Engineering Tool: Shrinkage & Cost Estimator
Calculate part weight, mold cavity dimensions accounting for shrinkage, and material cost — all locally in your browser.
Equivalents & Cross-References
| Equivalent / Alternate | Action |
|---|---|
| Solvay Radel R-5000 | |
| BASF Ultrason P | |
| Sumitomo SumikaExcel PPSU |
Frequently Asked Questions
How does PPSU Radel compare to polycarbonate (PC) for impact resistance?
At room temperature, polycarbonate's notched Izod impact (~700-900 J/m) is comparable to or slightly higher than PPSU (~690 J/m). The key difference emerges after environmental exposure: (1) PC loses 50%+ of its impact strength after 100 autoclave cycles due to hydrolysis-induced molecular weight reduction; PPSU retains >90% impact strength after 1000+ cycles. (2) PC stress-cracks rapidly on exposure to common disinfectants (quaternary ammonium compounds, alcohols); PPSU is virtually unaffected by the same chemicals. (3) At low temperatures (-40°C), PC undergoes a ductile-to-brittle transition; PPSU maintains ductile behavior down to -50°C. For reusable medical devices or aircraft components that must survive both sterilization and chemical exposure while retaining impact resistance, PPSU is specified over PC despite its 5-8× higher raw material cost.
Why is PPS brittle compared to PEEK?
PPS has very low elongation at break (1-3% for glass-filled, 3-5% for unfilled) compared to PEEK (20-50%). This is inherent to PPS's highly crystalline, rigid molecular structure. PPS should not be used in applications subject to impact loading or snap-fit assembly. If toughness is required, consider PEEK or PPA instead.
Can PPS be used for potable water applications?
Yes, specific PPS grades meet NSF/ANSI 61 for potable water contact. Fortron PPS (linear type) is more commonly certified for water applications than cross-linked Ryton PPS. Verify compliance with the specific grade and manufacturer before specifying for drinking water applications.
What is the difference between Ryton and Fortron PPS?
Ryton (Chevron Phillips) is cross-linked PPS with slightly higher molecular weight, offering marginally better mechanical properties. Fortron (Celanese, now subsidiary of Qingdao) is linear PPS with better weld line strength and less flash during molding. Both offer similar chemical and thermal resistance — selection is typically driven by availability and specific grade properties.
Does PPS absorb moisture?
PPS has exceptionally low moisture absorption (0.02-0.05% at saturation), one of the lowest among engineering plastics. This means excellent dimensional stability in humid environments and no significant property changes after water exposure. Minimal drying is needed before processing (2-3 hours at 120-150°C is sufficient).
Can PPS be welded?
Yes. PPS can be welded by vibration welding, ultrasonic welding, and hot plate welding — all common in automotive sensor and fuel system assembly. Weld strength typically reaches 70-80% of parent material strength. Linear PPS (Fortron) generally welds better than cross-linked PPS (Ryton) due to more consistent melt flow.
Related Diagnostics & Materials
PEEK Polyetheretherketone: High-Performance Polymer...
Polyetheretherketone (PEEK) is a colorless organic thermoplastic polymer in the polyaryletherketone (PAEK) family,...
Ultem PEI (Polyetherimide): High-Temperature Amorphous...
Polyetherimide (PEI), best known by Sabic's trade name Ultem, is an amorphous high-performance thermoplastic...
PTFE Teflon: Ultimate Chemical Resistance & Low-Friction...
Polytetrafluoroethylene (PTFE), widely known by the trade name Teflon, is a fluoropolymer with the lowest...
PPS Ryton: Polyphenylene Sulfide High-Temp...
Polyphenylene sulfide (PPS), best known by Solvay's trade name Ryton, is a semicrystalline high-performance...
LCP Vectra: Liquid Crystal Polymer for Micro-Molding &...
Liquid Crystal Polymer (LCP), best known by Celanese's trade name Vectra, is a unique class of thermotropic...
Vespel Polyimide: Extreme-Temperature Polymer for...
Polyimide (PI), commercially known as DuPont Vespel, is the highest-temperature-rated polymer commercially...
PAI Torlon: Polyamide-Imide Extreme-Performance Polymer...
Polyamide-imide (PAI), commercially known as Solvay Torlon, occupies the performance space between PEEK and...
PES Veradel: Polyethersulfone Transparent High-Temp...
Polyethersulfone (PES), commercially known as Solvay Veradel or BASF Ultrason E, is an amorphous high-temperature...
References & Industry Standards
- ASTM International. Standard Specifications for Engineering Plastics & Thermoplastics. astm.org
- UL Prospector. Plastics & Elastomers Material Database. ulprospector.com
- MatWeb. Material Property Data for Engineering Thermoplastics. matweb.com
- ISO 1043. Plastics — Symbols and Abbreviated Terms. iso.org