Acrylonitrile Butadiene Styrene (ABS)

Acrylonitrile Butadiene Styrene (ABS)

ABS stands for Acrylonitrile Butadiene Styrene.
ABS is an impact-resistant engineering thermoplastic & amorphous
polymer.
ABS is made up of three monomers: acrylonitrile, butadiene and styrene:
Acrylonitrile: It is a synthetic monomer produced from propylene and
ammonia. This component contributes to ABS chemical resistance & heat
stability
Butadiene: It is produced as a by-product of ethylene production from
steam crackers. This component delivers toughness & impact strength to
ABS polymer
Styrene: It is manufactured by dehydrogenation of ethyl benzene. It
provides rigidity & processability to ABS plastic
Acrylonitrile Butadiene Styrene (ABS)
Content
• How ABS is Made?
• Key Properties of ABS Plastic
• Limitations of ABS
• ABS Blends – Thermoplastic Alloy
• Applications of Acrylonitrile Butadiene Styrene (ABS)
• ABS Processing Conditions
• ABS Properties for 3D Printing
• ABS Recycling and Toxicity
 How ABS is Made?
• ABS is produced by emulsion or continuous mass technique. The
chemical formula of Acrylonitrile Butadiene Styrene is
(C8H8·C4H6·C3H3N)n.
• The natural material is an opaque ivory color and is readily colored
with pigments or dyes.

Molecular Structure of Acrylonitrile Butadiene Styrene

 How ABS is Made?
ABS is a strong & durable, chemically resistant resin but gets easily
attacked by polar solvents.
It offers greater impact properties and slightly higher heat distortion
temperature than HIPS.
Acrylonitrile Butadiene Styrene has a broad processing window and can be
processed on most standard machinery. It can be injection-molded, blow-
molded, or extruded.
It has a low melting temperature making it particularly suitable
for processing by 3D printing on an FDM machine.
ABS falls between standard resins (PVC, polyethylene, polystyrene, and so
on) and engineering resins (acrylic, nylon acetal…)
 Key suppliers of ABS plastics
Key suppliers of ABS plastics include:
SABIC,
RTP Company,
LG Chem,
Ineos etc.
3D Printing ABS grades are readily available from 3D Systems,
Stratasys, Techmer Engineered Solutions…
 Key Properties of ABS Plastic
ABS is an ideal material of choice for various structural applications,
thanks to its several physical properties such as:
• High rigidity
• Good impact resistance, even at low temperatures
• Good insulating properties
• Good weldability
• Good abrasion and strain resistance
• High dimensional stability (Mechanically strong and stable over time)
• High surface brightness and excellent surface aspect
 Key Properties of ABS Plastic
• ABS shows excellent mechanical properties i.e.
• it is hard and tough in nature and thus delivers good
impact strength.
• Acrylonitrile Butadiene Styrene offers a high degree of
surface quality.
• Apart from these characteristics, Acrylonitrile
Butadiene Styrene exhibits good electrical insulating
properties.
 Chemical Properties of ABS
•Very good resistance to diluted acid and
alkalis
•Moderate resistance to aliphatic
hydrocarbons
•Poor resistance to aromatic hydrocarbons,
halogenated Hydrocarbons and alcohols
Mechanical Properties of ABS
Elongation at Break 10 - 50 %
Elongation at Yield 1.7 - 6 %
Flexibility (Flexural Modulus) 1.6 - 2.4 GPa
Hardness Shore D 100
Stiffness (Flexural Modulus) 1.6 - 2.4 GPa
Strength at Break (Tensile) 29.8 - 43 MPa
Strength at Yield (Tensile) 29.6 - 48 MPa
Toughness (Notched Izod Impact at
200 - 215 J/m
Room Temperature)
Toughness at Low Temperature
(Notched Izod Impact at Low 20 - 160 J/m
Temperature)
Young Modulus 1.79 - 3.2 GPa
Electrical Properties of ABS
Arc Resistance 60 - 120 sec
Dielectric Constant 2.7 - 3.2
Dielectric Strength 15.7 - 34 kV/mm
Dissipation Factor 50 - 190 x 10-4
14 - 16 x
Volume Resistivity 15
10 Ohm.cm
Check Out Several Other Properties (Physical,
Chemical, Fire Performance) of ABS in Detail!
• ABS is readily modified both by the addition of additives and by
variation of the ratio of the three monomers Acrylonitrile, Butadiene
and Styrene.
• Heat stabilizers, hydrolysis stabilizers, lubricants, UV stabilizers etc.
are being used in non-reinforced and reinforced grades to increase
specific material properties.
Hence, grades available include:
High and medium impact
High heat resistance, and
Electroplatable
Check Out Several Other Properties (Physical,
Chemical, Fire Performance) of ABS in Detail!
• Fire retardant grades can be obtained either by
the inclusion of fire retardant additives or by
blending with PVC.
• In order to increase stiffness, impact resistance
and dimensional stability, ABS can be reinforced
with fibers, fillers, minerals, etc. It can lead to
loss on transparency, yield strength
 Limitations of ABS
• Poor weathering resistance
• Ordinary grades burn easily and continue to burn once the flame is
removed
• Scratches easily
• Poor solvent resistance, particularly aromatic, ketones and esters
• Can suffer from stress cracking in the presence of some greases
• Low dielectric strength
• Low continuous service temperature
 ABS Blends – Thermoplastic Alloy
To overcome some of these
limitations,
• ABS can be readily blended or
alloyed with other polymers such
as PA, PBT, PC etc.
• This blending with polymers
further increases the range of
properties available such as
mechanical, thermal & more.
 Applications of Acrylonitrile Butadiene Styrene (ABS)

• Several properties like high impact strength, heat performance etc.

make ABS suitable for use in automotive, home appliances,
electronics, building & construction, transportation industries and
many more.
Automotive Applications – ABS is the preferred engineering plastic
when it comes to dealing with automotive applications.
• There has been an increasing focus on weight reduction in
automotive.
• Being a great substitute to metals, ABS has been extensively used in
manufacturing automotive parts.
 Applications of Acrylonitrile Butadiene Styrene (ABS)
Acrylonitrile Butadiene Styrene applications in automotive and transportation include:
Instrument panels
Pillar trim
Dashboard components
Door liners and handles
Seat backs, seat belt components, etc.

Appliances – Used of ABS in appliances include appliance

control panels, housings (shavers, vacuum cleaners, food
processors), refrigerator liners, etc. Household and consumer
goods are the major applications of ABS. Keyboard keycaps are
commonly made out of ABS.
 Electrical &
Applications Electronics Applications –
ABS provides good all-round
performance for electronic
enclosures, computer keyboards
etc.
Applications
• Pipes and fittings made from ABS are widely used as they are easier
to install and do not rot, rust or corrode. Under proper handling, they
withstand earth loads and shipping & can also resist mechanical
damage, even at low temperatures.

ABS is further used to make legos, instruments, sports equipment,

gardening tools, medical applications include manufacturing
nebulizers, compressors and more.
 ABS Processing Conditions
• Acrylonitrile-butadiene Styrene (ABS) has a broad processing window and can be
processed on most standard machinery.

• Injection Molding
• Pre-drying is not always needed for injection molding with a vented cylinder. In case drying is
needed then 4 hours at 80°C is generally sufficient. Signs of moisture are stripes, streaks or
bubbles in the molding and if any of these are seen then the material should be pre-dried
• Melt temperature: 210-270°C
• Mold temperature: of 40-70°C
• Material Injection Pressure: 50 - 100 MPa
• Injection Speed: Moderate - High
• Extrusion
• Pre-Drying: 3 hours at 70-80°C
• Extrusion temperature: 210 to 240°C
• Screw Design: L/D ratio of 25-30 is recommended
 ABS Properties for 3D Printing
• ABS is one of the most versatile materials available for 3D
printing today. ABS comes in the form of a long filament wound
around a spool. The 3D Printing process used with ABS is the FDM
(Fusion Deposition modelling) process where material is heated and
squeezed through a fine nozzle to build your design in 250 micron
layers.
• Objects printed with ABS boast slightly higher strength, flexibility, and
durability. It is a great material for prototyping and it can be easily
machined, sanded, glued and painted.

One of main competitors of 3D Printing ABS is PLA. Unlike ABS, PLA is

a renewably derived plastic. It is therefore biodegradable whereas
ABS is only biocompatible. However, like many plastic materials, ABS
is recyclable.
 ABS Recycling and Toxicity
• As mentioned above ABS plastic is biocompatible and recyclable material.
ABS does not have its own plastic number. Products made with ABS use
recycling number #9.
ABS is 100% recyclable
• ABS is non-toxic and harmless
• It doesn't have any known carcinogens, and there are no known adverse
health effects related to exposure to its exposure. It is stable and non-
leaching.
Recycled ABS can be blended with virgin material to produce products with
lower cost while preserving the high quality.
 Acrylonitrile-butadiene-styrene (ABS)
Production and Manufacturing Process
ABS was patented in 1948 and introduced commercially by Borg-Warner in
1954. There are three main polymerisation processes used:
(1) Emulsion process (oldest and least clean);
(2) Suspension (blending high rubber content medium with SAN);
(3) Continuous mass (clean, cost effective but lacks flexibility).
• The continuous mass process is seen as the preferred route because the
reaction does not take place in the aqueous phase. There is less effluent
that needs disposal and energy requirements are lower. With its improved
technology, the process can produce resins with enhanced colour
consistency, making painting unnecessary in certain applications.
 Acrylonitrile-butadiene-styrene (ABS)
Production and Manufacturing Process
• However, the emulsion polymerisation process, which was commonly used
in plants built before the mid-1980s, provides more flexibility in its product
range than the mass process. The batch emulsion is used in the production
of high impact grades.
• A hybrid emulsion/mass process has also been developed. It combines the
features of the emulsion process, which forms polybutadiene latex and
grafts styrene and acrylonitrile, and the mass process, which makes the
styrene acrylonitrile component. This approach permits the production of a
wide range of ABS products.
• Advances in technology include claims by BASF of improved efficiencies
and output. LG Chemical claims to have developed a new high productivity
route and EniChem has invested in a new flexible process.
Styrenics (ABS)
History – In WWII there was a push to develop alternatives to rubber
due to America’s primary source of rubber (Asia) being cut off.
Experimentation with Styrene Butadiene Rubber led to the
development of Acrylonitrile Butadiene Styrene or ABS
Structure –
Styrene
Acrylonitrile
Butadiene
 Styrenics (ABS) – Forms
The Terpolymer ABS is commonly alloyed with other materials like
Polycarbonate and Polyester for improved properties, but the
terpolymer alone can be modified by changing the ratios of the
different monomers to obtain a wider range of properties.
Styrenics (ABS) - Considerations
Density – The specific gravity of ABS is 1.05, the same as polystyrene

Crystallinity – Amorphous

Hygroscopy – Should be dried at 190°F for 3-4 hrs or until it reaches a moisture
content of < 0.04%

Tg – 200°F

Tm – 410°F
Styrenics (ABS) - Considerations
Price – Around $0.95/pound depending on previously mentioned
factors

Mechanical Properties – ABS has good to excellent mechanical

properties. It is commonly used for ABS pipe and housings for
computers and other electronic equipment.

Chemical Resistance – good chemical resistance, but it is not resistant

to solvents, much like Polycarbonate and Polystyrene, so be a little
careful what you dump down the drain if you have ABS pipes!
Styrenics (ABS) - Considerations
Optical Properties- ABS is generally not clear, there are a few clear
grades, but they are primarily used in the medical field. It can attain a
glossy finish with the proper mold polish.
Flammability- Burns freely and gives off a black sooty smoke

Electrical Properties- It can be made conductive with plating, but

otherwise its electrical properties would be considered good.
Styrenics (ABS) - Considerations
Weatherability- ABS doesn’t weather as well as some other materials
unless highly modified or coated.

Processability – Easily processed using most common methods

Thermal Sensitivity – ABS has good thermal stability, it will degrade, but
not in a short period of time at normal processing temperatures.
Styrenics (ABS) - Considerations
Decoration and Assembly – Easily decorated and assembled by most
means. The only real consideration is to not use solvent based paints
as they can weaken the substrate material.

Creep – Good to very good creep resistance

Recyclability – ABS may be recycled with

other styrenic materials
Styrenics (ABS) - Applications
• Consumer goods – From toys to tool housings to computers and other
electronics, ABS has a wide variety of uses.
Styrenics (ABS) - Applications
• Medial Applications- ABS is commonly used in
the medical field because of its ease of sterilization,
decoration, and assembly.

• Automotive- ABS has been used to make body

panels, wheel covers and interior trim
components in the automotive industry.
Styrenics (ABS) - Applications
• Packaging- ABS is not commonly used in food packaging due to poor
permeability, but it can be formed into containers for non-perishable
items

• Construction- The most common use for ABS in the construction

industry is in waste piping.
Styrene Based Polymers (Styrenics)
Introduction of polystyrene
Monomer preparation
Polymerization
- Mass polymerization
- Suspension polymerization
- Solution polymerization
Available grades
Properties related to structure
General properties
Processing behaviour
Processing techniques
Applications
 Acrylonitrile Butadiene Styrene
(ABS) Copolymer
CH2-CH-CH 2-CH=CH-CH2-CH2-CH n
CN

 These materials are complex blends and copolymers of

Acrylonitrile, butadiene and styrene.

 In most types, Acrylonitrile and styrene are grafted onto a

polybutadiene backbone. The product also contain
unreacted polybutadiene and some acrylonitrile styrene
copolymer.
 The reasons for its widespread acceptance are high impact
resistance, good stiffness, excellent surface quality, high
dimensional stability at elevated temperatures.
 Its main disadvantages are lack of transparency, poor
weathering resistance, poor flame resistance.
 ABS Preparation
 Styrene and Acrylonitrile are added to polybutadiene latex
and the mixture is warmed to about 50°C to allow absorption of
the monomers.

 Water soluble initiator is added to polymerize styrene and

Acrylonitrile.

 The resultant materials will be a mixture of Polybutadiene,

polybutadiene grafted with Acrylonitrile and Styrene, and
Styrene-Acrylonitrile copolymer.
 General Properties
 Chemical and Solvent resistance
 Generally resistant to alkalis and acids but not
concentrated oxidizing acids.
 Dissolved by many aromatic and chlorinated hydrocarbons,
esters and ketones.

 Maximum Service temperature

 UL temperature index 60-75°C.
 Alloy with Polycarbonate may be as high as 95°C.

 Flammability
 Standard grades are considered as slow burning and
usually meet the UL HB requirement.
 The material burns with a smoky yellow flame emitting a
pungent gas.
 Properties of ABS
Properties Value Unit
Specific gravity 1.03-1.06 --
Tensile Strength 30-52 MPa
Tensile modulus 2070-2760 MPa
Flexural modulus 2200-3030 MPa
Elongation at break 2.3-3.5 %
Impact Strength (Izod ) 134-320 J/m
Hardness R 105-112 ---
HDT (under 1.82 MPa load.) 93-104 °C
Glass transition temperature 105-115 °C
Dielectric Strength 16-31 KV/mm
Processing Considerations
 May absorb upto 0.3% moisture and therefore must be
stored under dry condition.

 Greater tendency to degradation than PS during

processing so important not to overheat. Avoid too high
screw speed and back pressure during moulding.

 Generally less free flowing than PS particularly with heat

resistance grades.

 Being an amorphous, the materials have a low

moulding shrinkage.
 Processing Techniques
Injection Moulding

Typical Injection Moulding conditions

 Recommended melt temperatures 220-280 °C.
 Typical mould temperature is 40–90 °C.
 Injection pressures of 69-138 MPa.
 L/D ratio is 20:1 and Compression ratio of 2:1 to 3:1.
Extrusion

Typical extrusion conditions

 Melt temperatures 205-250 °C.
 Temperature profile 192-250°C.
 Recommended screw L/D ratio 20:1 to 36:1.
 Recommended Compression ratio 2.5:1 to 3:1.
 Thermoforming
 ABS can be thermoformed over a temperature range of
130 to 190°C.

 The optimum conditions depend on material

grade,part design, draw ratio, sheet thickness and
forming technique.
 Electroplating
 ABS is the best material for electroplating.

 The polymer is treated by an acid etching process which

dissolves out some of the rubber particles at or near the
polymer surface. After sensitization and activation
electroless metal deposition processes are carried out .
 Trade names
GE, India - Cycolac
Bhansali polymers , India - Abstron
Kanegafuchi chemical, Japan - Kane Ace
Bayer , DE - Novodur
Polychemical co, Taiwan - Polylac
 Applications of ABS
Automobile
 Radiator grills, head light housing, seat belt, head lamp
fixtures, door knobs, two wheeler front noise, water panel,
helmet, electroplated parts, mirror housing and wheel
covers. In the vehicle construction industry.

Agriculture
 Drinking water system, water vent systems and
irrigation systems.
 Household
 Plumbing fixtures, table edging, sliding doors, window
trucks, refrigerators liners, refrigerator door handles,
pipe fittings, ventilator system components, picnic boxes,
food processors, coffee maker leads, microwave
oven tops.

Medical
 IV fluid monitoring controllers, blood glucose meter,
surgical clips, emergency intravenous infusion pump,
scanner body, ECG / EEG body frames, cabinets for
medical kit, breathing exerciser.
 Applications

ABS Car Dashboard ABS car interiors

ABS Car bumper ABS meter box

 Blends of ABS
 ABS/PC
Increase in HDT up to 130°C.

 ABS/PVC (80:20)
Fire retarding ABS type material.

 ABS/PVC (10:90)
Impact modified form of unplasticised PVC.

 ABS/Acrylic material
A reasonable transparent ABS-type polymer.