PPSU Radel: Polyphenylsulfone Maximum-Toughness Medical & Aerospace Polymer
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.
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.
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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