Polyphenylsulfone PPSU
Poly(biphenyl ether sulfone), repeat unit C24H16O4S, made from 4,4'-biphenol and 4,4'-dichlorodiphenyl sulfone · CAS 25608-64-4
Also known as R-5000
Polyphenylsulfone (PPSU) is an amorphous, high-temperature thermoplastic made from 4,4'-biphenol and 4,4'-dichlorodiphenyl sulfone.
Evidence level
2 of 5
Lab-measured
- 0Predicted only. No one has made it, or no measurement exists.
- 1Calculated. Only calculated or predicted values from sources.
- 2Lab-measured. Measured properties with their conditions stated.
- 3Space-relevant tests. Measured in conditions relevant to space, such as vacuum or atomic oxygen.
- 4Ground-qualified. Qualified for an application on the ground.
- 5Flown or field-proven. Flight or field results exist.
Heat
207 degC
Glass transition
220 degC
Stiffness
2340 MPa
Repeated sterilisation
More than 1000 cycles
Recipe, share of the weight
- C 72.0%Carbon
- H 4.0%Hydrogen
- O 16.0%Oxygen
- S 8.0%Sulfur
Best for
Parts that must be steam sterilised many times and keep their shape near 200 degC, such as surgical instruments and flame-rated aircraft interior parts
Weakest at
UV and weathering: the polysulfone family is known to weather, and no numeric UV or atomic oxygen result for PPSU was found
Risk at a glance
- People None found. Not classified hazardous
- If it fails High. Decomposed melt in the barrel
- Corrosion Moderate. The UL relative thermal index is 105 degC, which sets the long-term limit for this grade.
Quick facts: PPSU
| Property | Value | Basis |
|---|---|---|
| Density | 1.29 g/cm³ | 1 sourced value |
| Yield strength | 74 MPa | 1 sourced value |
| Tensile strength | 69.6 MPa | 1 sourced value |
| Young's modulus | 2.34 GPa | 1 sourced value |
| Thermal expansion (CTE) | 55 ppm/K | 1 sourced value |
What is the density of Polyphenylsulfone (PPSU)?
Polyphenylsulfone (PPSU) has a density of 1.29 g/cm³. The source and test conditions are listed in the properties table on this page.
What is the coefficient of thermal expansion of Polyphenylsulfone (PPSU)?
Polyphenylsulfone (PPSU) has a coefficient of thermal expansion of 55 ppm/K. The source and test conditions are listed in the properties table on this page.
What is the yield strength of Polyphenylsulfone (PPSU)?
Polyphenylsulfone (PPSU) has a yield strength of 74 MPa. The source and test conditions are listed in the properties table on this page.
What is the tensile strength of Polyphenylsulfone (PPSU)?
Polyphenylsulfone (PPSU) has a tensile strength of 69.6 MPa. The source and test conditions are listed in the properties table on this page.
What is the Young's modulus of Polyphenylsulfone (PPSU)?
Polyphenylsulfone (PPSU) has a Young's modulus of 2.34 GPa. The source and test conditions are listed in the properties table on this page.
What is Polyphenylsulfone (PPSU) used for?
Uses recorded in the sources include Aircraft cabin interior parts; Surgical instruments and hospital goods, steam sterilised; Electrical equipment parts.
Why it exists
Polyphenylsulfone (PPSU) is an amorphous thermoplastic whose backbone carries a biphenyl unit beside its ether and sulfone links. That biphenyl unit separates it from PES. It was chosen for this profile because it is the sulfone polymer that its supplier markets for repeated steam sterilisation, with a deflection temperature of 207 degC at 1.8 MPa and a glass transition of 220 degC on the Radel R-5000 sheet. The same sheet also gives a V-0 flame rating for the transparent grade.
Where it's used
Aircraft cabin interior parts
The Radel R-5000 sheet lists FAA FAR 25.853a among its agency ratings, the flammability rule for aircraft cabin interiors. The sheet does not name a part.
Surgical instruments and hospital goods
The Radel R-5000 sheet lists surgical instruments, hospital goods and ISO 10993, and says the grade passes more than 1000 steam autoclave cycles without cracking.
Electrical equipment
Wikipedia says polysulfones serve electrical equipment, vehicle construction and medical technology. It gives no PPSU grade for these uses.
Recipe
Poly(biphenyl ether sulfone), repeat unit C24H16O4S, made from 4,4'-biphenol and 4,4'-dichlorodiphenyl sulfone
PPSU is made by polycondensation of 4,4'-biphenol with 4,4'-dichlorodiphenyl sulfone, with a base to form the salt and remove the hydrogen halide (Wikipedia names the two monomers). The repeat unit is C24H16O4S, derived by Space Mushroom from those monomers. Wikipedia notes that PPSU has a large amount of biphenyl, which gives it higher heat resistance than PSU, and that it has no isopropylidene group.
| Ingredient | Atoms per unit | Share of the weight | What it does |
|---|---|---|---|
| Carbon C | 24 | 72.0% | Forms the four phenylene rings of each repeat unit, two from the biphenyl and two from the sulfone unit. |
| Hydrogen H | 16 | 4.0% | Four hydrogens on each of the four phenylene rings. |
| Oxygen O | 4 | 16.0% | Two ether oxygens and the two oxygens of the sulfone group. |
| Sulfur S | 1 | 8.0% | Sulfone group, which gives rigidity and heat resistance. |
Weight shares are calculated from standard atomic weights.
What it can do
Heat
207 degC
measured
The Radel R-5000 sheet gives a deflection temperature of 207 degC at 1.8 MPa (ASTM D648, unannealed).
Glass transition
220 degC
measured
The Radel R-5000 sheet gives 220 degC by ASTM E1356, and the BASF P 3010 DSC value is also 220 degC.
Stiffness
2340 MPa
measured
The Radel R-5000 sheet gives a tensile modulus of 2340 MPa at 23 degC (ASTM D638, 3.18 mm).
Repeated sterilisation
More than 1000 cycles
measured
The Radel R-5000 sheet says the grade passed more than 1000 steam autoclave cycles at 132 degC with morpholine, without cracking or crazing.
How it compares
PPSU and PES are both sulfone polymers without the bisphenol-A unit of PSU. PPSU adds a biphenyl unit from 4,4'-biphenol, which Wikipedia links to higher heat resistance. Its datasheets in this run give a glass transition close to PES, and the Radel sheet says its toughness is superior to other high-temperature resins. Its water uptake is reported on ASTM D570 for the R-5000 grade, while the PES profile uses a similar-to-ISO 62 method, so compare the two only after checking the method. The UL relative thermal index for P 3010 is 105 degC, which is lower than the IEC 60216 index in the PES profile. The two indices are different tests and should be read as such.
The same measurements for each material, so you can compare them. Each row names the key condition under the value; the full conditions and methods are in the numbered notes under Technical details. Other materials are shown beside it; each was measured under its own conditions, so open its page before comparing closely. Compare every grade in the family.
| Measurement | PPSU | PAI | PBI | PBO (Zylon) | PEEK | PEI | PEK | PEKK | PES | PPS | PSU |
|---|---|---|---|---|---|---|---|---|---|---|---|
| Thermal behavior and safety | |||||||||||
| Deflection temperature under load, 1.8 MPa, Radel R-5000 | 207 °C3 | 278 °C | 435 °C | no data | no data | 173 °C | 163 °C | 164 °C | 205 °C | 400 °F | 174 °C |
| Deflection temperature under load, 1.8 MPa, Ultrason P 3010 NAT (other grade) | 197 °C19 | 278 °C | 435 °C | no data | no data | 173 °C | 163 °C | 164 °C | 205 °C | 400 °F | 174 °C |
| Relative thermal index, electrical, impact and strength, Ultrason P 3010 NAT | 105 °C21 | no data | no data | no data | no data | no data | no data | no data | 180 °C | no data | no data |
| Lifetime and stability | |||||||||||
| Steam sterilisation, cycles passed without cracking or crazing | > 1000 cycles18 | no data | no data | no data | no data | no data | no data | no data | no data | no data | no data |
| Physical and electrical | |||||||||||
| Density, unreinforced transparent grade | 1.29 g/cm³1 | 1.41 g/cc | 1.276 g/cm³ | 1.398 g/cm³ | 1.3 g/cm³ | 1.34 g/cm³ | 1.3 g/cm³ | 1.29 g/cm³ | 1370 kg/m3 | 1.36 g/cm³ | 1.22 g/cm³ |
| Temperature behavior | |||||||||||
| Glass transition temperature, Radel R-5000 | 220 °C2 | 275 °C | 425 °C | no data | no data | 186 °C | 160 °C | 165 °C | 225 °C | 90 °C | 190 °C |
| Glass transition temperature, DSC, Ultrason P 3010 NAT (other grade) | 220 °C20 | 275 °C | 425 °C | no data | no data | 186 °C | 160 °C | 165 °C | 225 °C | 90 °C | 190 °C |
| Other measurements | |||||||||||
| Tensile modulus, Radel R-5000 | 2340 MPa4 | 4136 MPa | 5.9 GPa | 147.1 GPa | no data | 3200 MPa | 4300 MPa | 4000 MPa | 2640 MPa | 8.37×10^5 psi | 2480 MPa |
| Tensile strength, Radel R-5000 | 69.6 MPa5 | 138 MPa | 160 MPa | 5.34 GPa | no data | no data | no data | 116 MPa | no data | 200 MPa | 70.3 MPa |
| Tensile elongation at break, Radel R-5000 | 60 to 120 %6 | 20 % | 3 % | 3.52 % | no data | 50 % | 15 % | 3 to 10 % | no data | 2.5 % | 50 % |
| Tensile elongation at yield, Radel R-5000 | 7.2 %7 | 20 % | 3 % | 3.52 % | no data | 50 % | 15 % | 3 to 10 % | no data | 2.5 % | 50 % |
| Flexural modulus, Radel R-5000 | 2410 MPa8 | 4136 MPa | no data | no data | no data | 2400 MPa | 4000 MPa | 3.9 GPa | no data | 6.31×10^5 psi | 2690 MPa |
| Flexural strength at 5.0 percent strain, Radel R-5000 | 91 MPa9 | 165 MPa | no data | no data | no data | 100 MPa | 170 MPa | 180 MPa | no data | 20400 psi | 106 MPa |
| Notched Izod impact strength, 3.18 mm, Radel R-5000 | 690 J/m10 | 105 J/m | no data | no data | no data | 88 J/m | no data | no data | 7.5 kJ/m2 | no data | 69 J/m |
| Water absorption at equilibrium, Radel R-5000 | 1.1 %11 | 0.4 % | 0.4 % | no data | no data | 0.25 % | 0.6 % | 0.4 % | 2.2 % | 0.01 % | 0.3 % |
| Water absorption after 24 hours, Radel R-5000 | 0.37 %12 | 0.4 % | 0.4 % | no data | no data | 0.25 % | 0.6 % | 0.4 % | 2.2 % | 0.01 % | 0.3 % |
| Dielectric constant at 60 Hz, Radel R-5000 | 3.44 -13 | 4.2 - | 3.2 - | no data | no data | no data | no data | 3 - | 3.9 - | 3 - | 3.03 - |
| Dielectric strength, 3.18 mm, Radel R-5000 | 15 kV/mm14 | 580 V/mil | 21 kV/mm | no data | no data | no data | 23 kV/mm | 84 kV/mm | 37 kV/mm | 450 V/mil | 17 kV/mm |
| Refractive index, Radel R-5000 | 1.672 -15 | no data | no data | no data | no data | no data | no data | no data | 1.63 - | no data | no data |
| Melt mass-flow rate, 365 degC and 5.0 kg | 14 to 20 g/10 min16 | no data | no data | no data | no data | no data | no data | no data | no data | no data | 7 g/10 min |
| Molding shrinkage, flow direction, 3.18 mm | 0.7 %17 | no data | no data | no data | no data | no data | no data | no data | no data | no data | no data |
| Moisture absorption at equilibrium, 23 degC and 50 percent r.h., Ultrason P 3010 NAT | 0.6 %22 | 0.4 % | 0.4 % | no data | no data | 0.25 % | 0.6 % | 0.4 % | 2.2 % | 0.01 % | 0.3 % |
| Water absorption at equilibrium in water, 23 degC, Ultrason P 3010 NAT | 1.2 %23 | 0.4 % | 0.4 % | no data | no data | 0.25 % | 0.6 % | 0.4 % | 2.2 % | 0.01 % | 0.3 % |
| Linear thermal expansion coefficient, longitudinal, 23 to 80 degC, Ultrason P 3010 NAT | 55 E-6/K24 | 3.1×10^-5 1/°C | 23 10-6 K-1 | no data | no data | 5.2×10^-5 1/°C | 55 ppm/K | 23 µm/m/K | 52 E-6/K | 2.6×10^-5 cm/cm/°C | 5.6×10^-5 1/°C |
| Yield stress, tensile, 50 mm per min, Ultrason P 3010 NAT | 74 MPa25 | no data | no data | no data | no data | 110 MPa | 115 MPa | 110 to 120 MPa | 86 MPa | 13700 psi | no data |
| Notched Izod impact strength, 23 degC, Ultrason P 3010 NAT | 58 kJ/m226 | 105 J/m | no data | no data | no data | 88 J/m | no data | no data | 7.5 kJ/m2 | no data | 69 J/m |
| Electric strength, K20/K20, Ultrason P 3010 NAT | 44 kV/mm27 | 580 V/mil | 21 kV/mm | no data | no data | no data | 23 kV/mm | 84 kV/mm | 37 kV/mm | 450 V/mil | 17 kV/mm |
Why choose it, and why not
Good for
- Steam sterilisation: the Radel sheet gives more than 1000 cycles with morpholine, and the grade is also labelled for gamma and e-beam sterilisation.
- Flame-rated interiors: the Radel sheet gives a V-0 flammability rating for the transparent grade, and BASF's P 3010 yellow card gives V-0 at 1.5 mm and 3.0 mm.
- Parts that must keep their shape near 200 degC under a 1.8 MPa load.
Watch out for
- UV and weathering: the family is known to weather, and no PPSU UV number was read. Exposed surfaces need protection.
- Water uptake of about 1 percent at equilibrium changes dimensions, so close-tolerance parts need allowance.
- The long-term heat limit for the P 3010 grade is a UL relative thermal index of 105 degC, which is well below its 207 degC short-term deflection temperature.
- No atomic oxygen result for PPSU was found, so it is not shown to be space-qualified on the evidence in this profile.
PPSU is a tough, steam-sterilisable, flame-rated sulfone thermoplastic with well-documented datasheet values. Its long-term heat rating is lower than its deflection temperature suggests, and its UV and atomic oxygen behaviour remain unverified.
Technical details
For scientists and researchers. Everything above comes from the record below: every number with its method, its conditions and its source.
Other names and standards
The same grade under other systems, as datasheets and standards print them. Each code was checked against the page it comes from.
| System | Codes |
|---|---|
| Trade name | R-5000 |
Notes
The method, full conditions and any caveat for the numbered rows above.
| # | Measurement | Method | Conditions | Caveat |
|---|---|---|---|---|
| 1 | Density, unreinforced transparent grade | Value as printed in the Radel R-5000 technical data sheet, Physical table | grade Radel R-5000 (unreinforced, transparent)method standard ASTM D792 | — |
| 2 | Glass transition temperature, Radel R-5000 | Value as printed in the Radel R-5000 technical data sheet, Thermal table | grade Radel R-5000 (unreinforced)method standard ASTM E1356 | — |
| 3 | Deflection temperature under load, 1.8 MPa, Radel R-5000 | Value as printed in the Radel R-5000 technical data sheet, Thermal table | grade Radel R-5000 (unreinforced)load 1.8 MPaspecimen 3.18 mm, unannealedmethod standard ASTM D648 | — |
| 4 | Tensile modulus, Radel R-5000 | Value as printed in the Radel R-5000 technical data sheet, Mechanical table | grade Radel R-5000 (unreinforced)specimen 3.18 mmmethod standard ASTM D638 | — |
| 5 | Tensile strength, Radel R-5000 | Value as printed in the Radel R-5000 technical data sheet, Mechanical table. The sheet does not say whether this is the yield or the break value. | grade Radel R-5000 (unreinforced)specimen 3.18 mmmethod standard ASTM D638 | — |
| 6 | Tensile elongation at break, Radel R-5000 | Range as printed in the Radel R-5000 technical data sheet, Mechanical table | grade Radel R-5000 (unreinforced)point breakspecimen 3.18 mmmethod standard ASTM D638 | — |
| 7 | Tensile elongation at yield, Radel R-5000 | Value as printed in the Radel R-5000 technical data sheet, Mechanical table | grade Radel R-5000 (unreinforced)point yieldspecimen 3.18 mmmethod standard ASTM D638 | — |
| 8 | Flexural modulus, Radel R-5000 | Value as printed in the Radel R-5000 technical data sheet, Mechanical table | grade Radel R-5000 (unreinforced)specimen 3.18 mmmethod standard ASTM D790 | — |
| 9 | Flexural strength at 5.0 percent strain, Radel R-5000 | Value as printed in the Radel R-5000 technical data sheet, Mechanical table | grade Radel R-5000 (unreinforced)strain 5.0 percentspecimen 3.18 mmmethod standard ASTM D790 | — |
| 10 | Notched Izod impact strength, 3.18 mm, Radel R-5000 | Value as printed in the Radel R-5000 technical data sheet, Impact table, in J/m (not converted) | grade Radel R-5000 (unreinforced)specimen 3.18 mmmethod standard ASTM D256 | — |
| 11 | Water absorption at equilibrium, Radel R-5000 | Value as printed in the Radel R-5000 technical data sheet, Physical table | grade Radel R-5000 (unreinforced)endpoint equilibriummethod standard ASTM D570 | — |
| 12 | Water absorption after 24 hours, Radel R-5000 | Value as printed in the Radel R-5000 technical data sheet, Physical table | grade Radel R-5000 (unreinforced)endpoint 24 hours immersionmethod standard ASTM D570 | — |
| 13 | Dielectric constant at 60 Hz, Radel R-5000 | Value as printed in the Radel R-5000 technical data sheet, Electrical table | grade Radel R-5000 (unreinforced)frequency 60 Hzspecimen 3.18 mmmethod standard ASTM D150 | — |
| 14 | Dielectric strength, 3.18 mm, Radel R-5000 | Value as printed in the Radel R-5000 technical data sheet, Electrical table. The sheet gives over 200 kV/mm at 0.0254 mm, which is not used because it is a thin-film figure. | grade Radel R-5000 (unreinforced)specimen 3.18 mmmethod standard ASTM D149 | — |
| 15 | Refractive index, Radel R-5000 | Value as printed in the Radel R-5000 technical data sheet, Optical table | grade Radel R-5000 (unreinforced, transparent)method standard ASTM D542 | — |
| 16 | Melt mass-flow rate, 365 degC and 5.0 kg | Range as printed in the Radel R-5000 technical data sheet, Physical table. Snake-case name used because no canonical name fits a mass-flow range at 365 degC and 5.0 kg. | grade Radel R-5000 (unreinforced)temperature 365 °Cload 5.0 kgmethod standard ASTM D1238 | Not comparable with the volume-flow rate printed for PES in its own profile. |
| 17 | Molding shrinkage, flow direction, 3.18 mm | Value as printed in the Radel R-5000 technical data sheet, Physical table. Snake-case name used because no canonical name fits a shrinkage figure in this file. | grade Radel R-5000 (unreinforced)specimen 3.18 mmmethod standard ASTM D955 | — |
| 18 | Steam sterilisation, cycles passed without cracking or crazing | Printed as greater than 1000 cycles, with the autoclave conditions in footnote 7 of the Radel R-5000 technical data sheet. Snake-case name used because no canonical name exists for a sterilisation cycle count. | grade Radel R-5000 (unreinforced)temperature 132 °C steamduration per cycle 30 minsteam pressure 0.19 MPastress 7.0 MPa in flexureadditive morpholine at 50 ppm | — |
| 19 | Deflection temperature under load, 1.8 MPa, Ultrason P 3010 NAT (other grade) | Value as printed in the BASF Ultrason P 3010 NAT product information, Thermal properties table. A different grade from R-5000. | grade Ultrason P 3010 NAT (unreinforced, medium viscosity)load 1.80 MPamethod standard ISO 75-1/-2, method A (HDT/A) | — |
| 20 | Glass transition temperature, DSC, Ultrason P 3010 NAT (other grade) | Value as printed in the BASF Ultrason P 3010 NAT product information, Properties table | grade Ultrason P 3010 NAT (unreinforced)method standard ISO 11357-1/-2, DSC at 10 °C per min | — |
| 21 | Relative thermal index, electrical, impact and strength, Ultrason P 3010 NAT | Value as printed on the UL yellow card in the BASF product information. The card prints 105 degC for all three indices, so this is the same figure for each. Not the IEC 60216 index used for PES. | grade Ultrason P 3010 NAT (pellets, all colours)min thickness 1.5 mmflame class V-0 at 1.5 mm and 3.0 mmbasis UL yellow card, RTI Elec, RTI Imp and RTI Str | — |
| 22 | Moisture absorption at equilibrium, 23 degC and 50 percent r.h., Ultrason P 3010 NAT | Value as printed in the BASF Ultrason P 3010 NAT product information, Properties table | grade Ultrason P 3010 NAT (unreinforced)temperature 23 °Crelative humidity 50 percentmethod standard similar to ISO 62 | — |
| 23 | Water absorption at equilibrium in water, 23 degC, Ultrason P 3010 NAT | Value as printed in the BASF Ultrason P 3010 NAT product information, Properties table | grade Ultrason P 3010 NAT (unreinforced)temperature 23 °Cmedium watermethod standard similar to ISO 62 | — |
| 24 | Linear thermal expansion coefficient, longitudinal, 23 to 80 degC, Ultrason P 3010 NAT | Value as printed in the BASF Ultrason P 3010 NAT product information (E-6/K as printed; the registry reads E-6/K as ppm/K) | grade Ultrason P 3010 NAT (unreinforced)temperature range 23 to 80 °Cdirection longitudinalmethod standard ISO 11359-1/-2 | — |
| 25 | Yield stress, tensile, 50 mm per min, Ultrason P 3010 NAT | Value as printed in the BASF Ultrason P 3010 NAT product information, Mechanical properties table | grade Ultrason P 3010 NAT (unreinforced)test speed 50 mm/mintemperature 23 °Cmethod standard ISO 527-1/-2 | — |
| 26 | Notched Izod impact strength, 23 degC, Ultrason P 3010 NAT | Value as printed in the BASF Ultrason P 3010 NAT product information, Mechanical properties table. Uses the same ISO 180/A method as the PES profile, so the two are directly comparable. | grade Ultrason P 3010 NAT (unreinforced)temperature 23 °Cmethod standard ISO 180/A | — |
| 27 | Electric strength, K20/K20, Ultrason P 3010 NAT | Value as printed in the BASF Ultrason P 3010 NAT product information, Electrical properties table | grade Ultrason P 3010 NAT (unreinforced)specimen treatment K20/K20method standard IEC 60243-1 | — |
Corrosion and compatibility
What happens when it meets other materials and environments.
| Environment | Concern | What happens |
|---|---|---|
| Ultraviolet light and outdoor weathering | not rated | No numeric UV ageing result for PPSU was read in this run. The BASF sheet says UV and water tests were run for outdoor acceptability, but gives no figure.1 |
| Humid air and immersion in water (23 degC) | low | PPSU takes up about 1 percent of water at equilibrium.2 |
| Long-term heat in air | moderate | The UL relative thermal index is 105 degC, which sets the long-term limit for this grade.3 |
| Steam, sterilising agents and chemicals | low | The sheet claims resistance to repeated steam sterilisation, acids, bases and detergents.4 |
| Gamma and electron-beam radiation | not rated | The sheet claims gamma and electron-beam sterilisability, but no dose figure was read.5 |
| # | Environment | Details | Test conditions |
|---|---|---|---|
| 1 | Ultraviolet light and outdoor weathering | BASF's P 3010 yellow card footnote f2 says the product was subjected to one or more of UV light, water exposure or immersion under UL 746C, and that outdoor acceptability is for UL to determine. The sheet prints no UV result. The Wikipedia polysulfone article says the family undergoes weathering and that this instability can be offset by adding other materials. | basis qualitative statements only; no dose, time or property change printedwavelengths not stated |
| 2 | Humid air and immersion in water (23 degC) | The Radel R-5000 sheet gives 1.1 percent water absorption at equilibrium (ASTM D570) and 0.37 percent after 24 hours. The BASF P 3010 grade gives 0.6 percent at 23 degC and 50 percent relative humidity, and 1.2 percent in water at 23 degC. The two grades use different test conditions, so the figures are not an exact match. | humidity 50 percent relative humidity (P 3010)immersion water at 23 °C, equilibriummethod standard ASTM D570 (R-5000); similar to ISO 62 (P 3010) |
| 3 | Long-term heat in air | The BASF P 3010 yellow card gives a relative thermal index of 105 degC for electrical, impact and strength properties at 1.5 mm, and the HDT is 197 degC at 1.80 MPa. The Radel R-5000 sheet gives 207 degC at 1.8 MPa as a short-term deflection test, not a service-life index. No long-term ageing time is printed for either grade. | basis UL yellow card relative thermal index, 1.5 mmshort term HDT 1.80 MPa (ISO 75 HDT/A and ASTM D648) |
| 4 | Steam, sterilising agents and chemicals | The Radel R-5000 sheet lists acid resistance, base resistance, chemical resistance, detergent resistance and high environmental stress crack resistance, and it lists steam sterilisation for more than 1000 cycles with morpholine. BASF describes the P 3010 grade as resistant to superheated steam and to stress cracking. Wikipedia says polysulfones resist hydrolysis, aqueous and alkaline media, and that they have low resistance to some solvents. No concentrations or times are given for chemical exposure. | basis qualitative feature list and the steam-cycle figure; no chemical concentration or time printed |
| 5 | Gamma and electron-beam radiation | The Radel R-5000 sheet lists Radiation (Gamma) Resistant, Radiation Sterilizable and E-beam Sterilizable among its features. It prints no absorbed dose, property change or test condition for radiation, so no radiation ageing number is stored. | basis feature list only |
Risks and side effects
Hazards to people, what happens when a cell overheats, and how the material is handled and stored.
For people
The Röchling SDS gives no classification, and BASF finds no health-hazardous effects when the product is processed as intended. Dust and hot melt still need care.
- The pellets and sheet
- The SDS lists no hazard statements and no pictograms. It notes that colour pigments may contain carbon black and titanium dioxide, which California lists under Proposition 65.
- Dust from machining
- Eye protection is advised. BASF applies the German MAK dust limit and asks for extraction above the barrel unit.
- Hot melt
- BASF says no harmful vapours form at or below 390 degC. Overheating decomposes the melt and gives off noxious odours.
If the polymer overheats or burns
The SDS says the product is combustible, and in a fire it gives off carbon monoxide and carbon dioxide. Decomposition temperatures printed in this run are the ones the SDS gives for ignition and decomposition.
- Gases
- Major fires need self-contained breathing apparatus and full protective equipment.
- Water
- Water, foam, dry powder or carbon dioxide are the suitable extinguishing media.
- Melt in the barrel
- BASF advises purging decomposed melt into the open air and cooling it quickly in water. Explosions are possible if decomposed melt is not removed.
Handling and storage
- Drying
- Dry the pellets at least 4 h at 130 to 150 degC before processing, because they take up moisture quickly.
- Storage
- Store the pellets in undamaged packaging, away from open flame and high temperatures.
Test details
The original wording and numbers from the sources, for readers who want them.
Failure risks
| Failure | Trigger and consequence |
|---|---|
| Decomposed melt in the barrelhigh severity | Melt above the 390 degC processing limit, or long residence in the barrelBASF says decomposed melt can build gas pressure, release violently around the nozzle or hopper, and produce noxious odours. The melt must be purged into the open air and cooled quickly in a water bath, and a hot plasticising unit must not be dismantled. |
| Moisture in the pelletsmoderate severity | Processing without dryingBASF says the pellets absorb moisture very rapidly and must be dried at least 4 h at 130 to 150 degC before processing. Wet pellets cause defects in moulded parts. |
| Dimensional change from water uptakelow severity | Immersion or long exposure to humid airEquilibrium water uptake is 1.1 percent (Radel R-5000) and 1.2 percent in water (P 3010), so close-tolerance parts need an allowance for swelling. |
| Long-term heat ageingmoderate severity | Continuous service near 105 degCThe UL relative thermal index of 105 degC for the P 3010 grade is the long-term limit printed for this family. The HDT of 207 degC is a short-term test and does not give a service life. |
Side effects on surrounding parts
| Affects | Effect |
|---|---|
| Operators and the processing area | Decomposing melt gives off noxious gases and odours during processing. BASF advises purging into open air and quick cooling in water. |
| Responders and the local air | In a fire the sheet names CO and CO2 as the special dangers. Major fires need self-contained breathing apparatus and protective equipment. |
Handling and storage
- Dry the pellets at least 4 h at 130 to 150 degC in a vacuum or dry-air drier before processing (BASF). The Radel sheet prints 149 degC for 2.5 h before injection moulding and 171 degC for 4 h before extrusion. Follow the grade's own sheet.
- Pellets can be stored indefinitely in undamaged packaging (BASF). Keep the product away from open flame, since the sheet describes it as combustible.
- Use eye protection when cutting or machining sheet and rod, and use the German MAK dust limits and extraction above the barrel unit.
Mitigations
- Fire: extinguish with water, foam, dry powder or carbon dioxide (Röchling SDS).
- Keep dust concentrations within the German MAK limit and ventilate the barrel unit with an extraction system (BASF).
Supply and geography
How common the raw materials are and where they come from.
Sulfur (sulfone-group feedstock for 4,4'-dichlorodiphenyl sulfone)
- Top producers (2025)
- China 22.6%, United States 9.6%, Russia 8.9%, Canada 6%
- Critical mineral lists
- US: not listed
- Recycling
- The USGS sulfur chapter says 2.5 to 5 million tons of spent sulfuric acid is reclaimed a year from petroleum refining. That is sulfuric acid, not elemental sulfur from polymers.
- Substitutes
- USGS: substitutes for sulfur at present or anticipated price levels are not satisfactory; some acids may replace sulfuric acid, usually at higher cost.
Documents
Datasheets, safety data sheets, papers and standards you can open.
| Document | Type | Year |
|---|---|---|
| Radel R-5000 Polyphenylsulfone technical data sheet (Syensqo, TDS-1445-en) | datasheet | 2024 |
| BASF Ultrason P 3010 NAT product information, with UL Yellow Card | datasheet | 2026 |
| Röchling Sustason PPSU safety data sheet | sds | 2022 |
| USGS Mineral Commodity Summaries 2026, Sulfur | report | 2026 |
Full record
The complete spore, as stored. Free to reuse under CC-BY-4.0. Images keep the licence shown with each one.
Show the full YAML
spore: profile
id: ppsu
spore_version: 0.2
family: high-performance-polymers
name: Polyphenylsulfone
abbreviation: PPSU
role: high-performance amorphous thermoplastic (poly(biphenyl ether sulfone), sold as Radel R-5000 by Syensqo and Ultrason P by BASF); the biphenyl sibling of PES and PSU
category: polymers
type: high-performance
summary: |
Polyphenylsulfone (PPSU) is an amorphous, high-temperature thermoplastic made from 4,4'-biphenol and 4,4'-dichlorodiphenyl sulfone. The biphenyl unit is the difference from PES. Syensqo's Radel R-5000 technical data sheet gives a deflection temperature of 207 degC at 1.8 MPa, a glass transition of 220 degC and a tensile modulus of 2340 MPa, and says the resin is steam sterilisable for more than 1000 cycles. The sheet also says its toughness is superior to other high-temperature engineering resins. BASF's Ultrason P 3010 NAT, a different grade, gives a UL relative thermal index of 105 degC. No atomic oxygen result and no numeric UV ageing result for PPSU was found in this run.
best_for: Parts that must be steam sterilised many times and keep their shape near 200 degC, such as surgical instruments and flame-rated aircraft interior parts
weakest_at: 'UV and weathering: the polysulfone family is known to weather, and no numeric UV or atomic oxygen result for PPSU was found'
identity:
formula: Poly(biphenyl ether sulfone), repeat unit C24H16O4S, made from 4,4'-biphenol and 4,4'-dichlorodiphenyl sulfone
cas: 25608-64-4
source: wiki-polysulfone
where: 'Wikipedia Polysulfone page, table Industrially relevant polysulfones: Polyphenylenesulfone (PPSU) CAS 25608-64-4. The repeat-unit formula C24H16O4S is derived by Space Mushroom from the two monomers named in wiki-ppsu (biphenol plus dichlorodiphenyl sulfone, minus 2 HCl), not printed by a source.'
designations:
- system: Trade name
code: R-5000
note: Radel R-5000, the transparent base grade. The same sheet lists colour versions CL 301 (smoke), NT (amber) and TR BU391 (blue), which are not profiled here.
source: radel-r5000-tds
where: Title block and Product Description, Radel R-5000 Polyphenylsulfone
tags:
environments: []
stresses:
- uv
- extreme-heat
applications:
- habitats-and-suits
- electronics-and-chips
properties:
- benchmark: density
label: Density, unreinforced transparent grade
value: 1.29
unit: g/cm3
scope: material
conditions:
grade: Radel R-5000 (unreinforced, transparent)
method_standard: ASTM D792
method: Value as printed in the Radel R-5000 technical data sheet, Physical table
status: ground
source: radel-r5000-tds
where: Physical table, Density / Specific Gravity, ASTM D792
- benchmark: glass_transition_temperature
label: Glass transition temperature, Radel R-5000
value: 220
unit: degC
scope: material
conditions:
grade: Radel R-5000 (unreinforced)
method_standard: ASTM E1356
method: Value as printed in the Radel R-5000 technical data sheet, Thermal table
status: ground
source: radel-r5000-tds
where: Thermal table, Glass Transition Temperature, ASTM E1356
- benchmark: heat_deflection_temperature
label: Deflection temperature under load, 1.8 MPa, Radel R-5000
value: 207
unit: degC
scope: material
conditions:
grade: Radel R-5000 (unreinforced)
load: 1.8 MPa
specimen: 3.18 mm, unannealed
method_standard: ASTM D648
method: Value as printed in the Radel R-5000 technical data sheet, Thermal table
status: ground
source: radel-r5000-tds
where: Thermal table, Deflection Temperature Under Load, 1.8 MPa, Unannealed, 3.18 mm
- benchmark: elastic_modulus
label: Tensile modulus, Radel R-5000
value: 2340
unit: MPa
scope: material
conditions:
grade: Radel R-5000 (unreinforced)
specimen: 3.18 mm
method_standard: ASTM D638
method: Value as printed in the Radel R-5000 technical data sheet, Mechanical table
status: ground
source: radel-r5000-tds
where: Mechanical table, Tensile Modulus (3.18 mm), ASTM D638
- benchmark: ultimate_tensile_strength
label: Tensile strength, Radel R-5000
value: 69.6
unit: MPa
scope: material
conditions:
grade: Radel R-5000 (unreinforced)
specimen: 3.18 mm
method_standard: ASTM D638
method: Value as printed in the Radel R-5000 technical data sheet, Mechanical table. The sheet does not say whether this is the yield or the break value.
status: ground
source: radel-r5000-tds
where: Mechanical table, Tensile Strength (3.18 mm), ASTM D638
- benchmark: elongation
label: Tensile elongation at break, Radel R-5000
value: 60
value_high: 120
bound: range
unit: '%'
scope: material
conditions:
grade: Radel R-5000 (unreinforced)
point: break
specimen: 3.18 mm
method_standard: ASTM D638
method: Range as printed in the Radel R-5000 technical data sheet, Mechanical table
status: ground
source: radel-r5000-tds
where: Mechanical table, Tensile Elongation, Break, 3.18 mm
- benchmark: elongation
label: Tensile elongation at yield, Radel R-5000
value: 7.2
unit: '%'
scope: material
conditions:
grade: Radel R-5000 (unreinforced)
point: yield
specimen: 3.18 mm
method_standard: ASTM D638
method: Value as printed in the Radel R-5000 technical data sheet, Mechanical table
status: ground
source: radel-r5000-tds
where: Mechanical table, Tensile Elongation, Yield, 3.18 mm
- benchmark: flexural_modulus
label: Flexural modulus, Radel R-5000
value: 2410
unit: MPa
scope: material
conditions:
grade: Radel R-5000 (unreinforced)
specimen: 3.18 mm
method_standard: ASTM D790
method: Value as printed in the Radel R-5000 technical data sheet, Mechanical table
status: ground
source: radel-r5000-tds
where: Mechanical table, Flexural Modulus (3.18 mm), ASTM D790
- benchmark: flexural_strength
label: Flexural strength at 5.0 percent strain, Radel R-5000
value: 91
unit: MPa
scope: material
conditions:
grade: Radel R-5000 (unreinforced)
strain: 5.0 percent
specimen: 3.18 mm
method_standard: ASTM D790
method: Value as printed in the Radel R-5000 technical data sheet, Mechanical table
status: ground
source: radel-r5000-tds
where: Mechanical table, Flexural Strength (5.0% Strain, 3.18 mm), ASTM D790
- benchmark: izod_impact
label: Notched Izod impact strength, 3.18 mm, Radel R-5000
value: 690
unit: J/m
scope: material
conditions:
grade: Radel R-5000 (unreinforced)
specimen: 3.18 mm
method_standard: ASTM D256
method: Value as printed in the Radel R-5000 technical data sheet, Impact table, in J/m (not converted)
status: ground
source: radel-r5000-tds
where: Impact table, Notched Izod Impact (3.18 mm), ASTM D256
- benchmark: moisture_absorption
label: Water absorption at equilibrium, Radel R-5000
value: 1.1
unit: '%'
scope: material
conditions:
grade: Radel R-5000 (unreinforced)
endpoint: equilibrium
method_standard: ASTM D570
method: Value as printed in the Radel R-5000 technical data sheet, Physical table
status: ground
source: radel-r5000-tds
where: Physical table, Water Absorption, Equilibrium, ASTM D570
- benchmark: moisture_absorption
label: Water absorption after 24 hours, Radel R-5000
value: 0.37
unit: '%'
scope: material
conditions:
grade: Radel R-5000 (unreinforced)
endpoint: 24 hours immersion
method_standard: ASTM D570
method: Value as printed in the Radel R-5000 technical data sheet, Physical table
status: ground
source: radel-r5000-tds
where: Physical table, Water Absorption, 24 hr, ASTM D570
- benchmark: dielectric_constant
label: Dielectric constant at 60 Hz, Radel R-5000
value: 3.44
unit: '-'
scope: material
conditions:
grade: Radel R-5000 (unreinforced)
frequency: 60 Hz
specimen: 3.18 mm
method_standard: ASTM D150
method: Value as printed in the Radel R-5000 technical data sheet, Electrical table
status: ground
source: radel-r5000-tds
where: Electrical table, Dielectric Constant (3.18 mm, 60 Hz), ASTM D150
- benchmark: dielectric_strength
label: Dielectric strength, 3.18 mm, Radel R-5000
value: 15
unit: kV/mm
scope: material
conditions:
grade: Radel R-5000 (unreinforced)
specimen: 3.18 mm
method_standard: ASTM D149
method: Value as printed in the Radel R-5000 technical data sheet, Electrical table. The sheet gives over 200 kV/mm at 0.0254 mm, which is not used because it is a thin-film figure.
status: ground
source: radel-r5000-tds
where: Electrical table, Dielectric Strength, 3.18 mm, ASTM D149
- benchmark: refractive_index
label: Refractive index, Radel R-5000
value: 1.672
unit: '-'
scope: material
conditions:
grade: Radel R-5000 (unreinforced, transparent)
method_standard: ASTM D542
method: Value as printed in the Radel R-5000 technical data sheet, Optical table
status: ground
source: radel-r5000-tds
where: Optical table, Refractive Index, ASTM D542
- benchmark: melt_flow_rate
label: Melt mass-flow rate, 365 degC and 5.0 kg
value: 14
value_high: 20
bound: range
unit: g/10 min
scope: material
conditions:
grade: Radel R-5000 (unreinforced)
temperature: 365 degC
load: 5.0 kg
method_standard: ASTM D1238
method: Range as printed in the Radel R-5000 technical data sheet, Physical table. Snake-case name used because no canonical name fits a mass-flow range at 365 degC and 5.0 kg.
status: ground
source: radel-r5000-tds
where: Physical table, Melt Mass-Flow Rate (365 degC/5.0 kg), ASTM D1238
note: Not comparable with the volume-flow rate printed for PES in its own profile.
- benchmark: molding_shrinkage
label: Molding shrinkage, flow direction, 3.18 mm
value: 0.7
unit: '%'
scope: material
conditions:
grade: Radel R-5000 (unreinforced)
specimen: 3.18 mm
method_standard: ASTM D955
method: Value as printed in the Radel R-5000 technical data sheet, Physical table. Snake-case name used because no canonical name fits a shrinkage figure in this file.
status: ground
source: radel-r5000-tds
where: Physical table, Molding Shrinkage - Flow (3.18 mm), ASTM D955
- benchmark: steam_sterilization_cycles
label: Steam sterilisation, cycles passed without cracking or crazing
value: 1000
bound: lower
unit: cycles
scope: material
conditions:
grade: Radel R-5000 (unreinforced)
temperature: 132 degC steam
duration_per_cycle: 30 min
steam_pressure: 0.19 MPa
stress: 7.0 MPa in flexure
additive: morpholine at 50 ppm
method: Printed as greater than 1000 cycles, with the autoclave conditions in footnote 7 of the Radel R-5000 technical data sheet. Snake-case name used because no canonical name exists for a sterilisation cycle count.
status: ground
source: radel-r5000-tds
where: Additional Information table, Steam Sterilization with Morpholine, and footnote 7
- benchmark: heat_deflection_temperature
label: Deflection temperature under load, 1.8 MPa, Ultrason P 3010 NAT (other grade)
value: 197
unit: degC
scope: material
conditions:
grade: Ultrason P 3010 NAT (unreinforced, medium viscosity)
load: 1.80 MPa
method_standard: ISO 75-1/-2, method A (HDT/A)
method: Value as printed in the BASF Ultrason P 3010 NAT product information, Thermal properties table. A different grade from R-5000.
status: ground
source: basf-p3010-nat
where: Thermal properties table, row HDT A (1.80 MPa), ISO 75-1/-2
- benchmark: glass_transition_temperature
label: Glass transition temperature, DSC, Ultrason P 3010 NAT (other grade)
value: 220
unit: degC
scope: material
conditions:
grade: Ultrason P 3010 NAT (unreinforced)
method_standard: ISO 11357-1/-2, DSC at 10 degC per min
method: Value as printed in the BASF Ultrason P 3010 NAT product information, Properties table
status: ground
source: basf-p3010-nat
where: Properties table, row Glass transition temperature, DSC (10 degC/min), ISO 11357-1/-2
- benchmark: relative_thermal_index
label: Relative thermal index, electrical, impact and strength, Ultrason P 3010 NAT
value: 105
unit: degC
scope: material
conditions:
grade: Ultrason P 3010 NAT (pellets, all colours)
min_thickness: 1.5 mm
flame_class: V-0 at 1.5 mm and 3.0 mm
basis: UL yellow card, RTI Elec, RTI Imp and RTI Str
method: Value as printed on the UL yellow card in the BASF product information. The card prints 105 degC for all three indices, so this is the same figure for each. Not the IEC 60216 index used for PES.
status: ground
source: basf-p3010-nat
where: UL Yellow Card table, row 1.5 mm, ALL colours (RTI Elec, RTI Imp, RTI Str)
- benchmark: moisture_absorption
label: Moisture absorption at equilibrium, 23 degC and 50 percent r.h., Ultrason P 3010 NAT
value: 0.6
unit: '%'
scope: material
conditions:
grade: Ultrason P 3010 NAT (unreinforced)
temperature: 23 degC
relative_humidity: 50 percent
method_standard: similar to ISO 62
method: Value as printed in the BASF Ultrason P 3010 NAT product information, Properties table
status: ground
source: basf-p3010-nat
where: Properties table, Moisture absorption, equilibrium 23 degC/50% r.h.
- benchmark: moisture_absorption
label: Water absorption at equilibrium in water, 23 degC, Ultrason P 3010 NAT
value: 1.2
unit: '%'
scope: material
conditions:
grade: Ultrason P 3010 NAT (unreinforced)
temperature: 23 degC
medium: water
method_standard: similar to ISO 62
method: Value as printed in the BASF Ultrason P 3010 NAT product information, Properties table
status: ground
source: basf-p3010-nat
where: Properties table, Water absorption, equilibrium in water at 23 degC
- benchmark: cte
label: Linear thermal expansion coefficient, longitudinal, 23 to 80 degC, Ultrason P 3010 NAT
value: 55
unit: E-6/K
scope: material
conditions:
grade: Ultrason P 3010 NAT (unreinforced)
temperature_range: 23 to 80 degC
direction: longitudinal
method_standard: ISO 11359-1/-2
method: Value as printed in the BASF Ultrason P 3010 NAT product information (E-6/K as printed; the registry reads E-6/K as ppm/K)
status: ground
source: basf-p3010-nat
where: Properties table, Coefficient of linear thermal expansion, longitudinal (23-80 degC), ISO 11359-1/-2
- benchmark: yield_strength
label: Yield stress, tensile, 50 mm per min, Ultrason P 3010 NAT
value: 74
unit: MPa
scope: material
conditions:
grade: Ultrason P 3010 NAT (unreinforced)
test_speed: 50 mm/min
temperature: 23 degC
method_standard: ISO 527-1/-2
method: Value as printed in the BASF Ultrason P 3010 NAT product information, Mechanical properties table
status: ground
source: basf-p3010-nat
where: Mechanical properties table, Yield stress, 50 mm/min, ISO 527-1/-2
- benchmark: izod_impact
label: Notched Izod impact strength, 23 degC, Ultrason P 3010 NAT
value: 58
unit: kJ/m2
scope: material
conditions:
grade: Ultrason P 3010 NAT (unreinforced)
temperature: 23 degC
method_standard: ISO 180/A
method: Value as printed in the BASF Ultrason P 3010 NAT product information, Mechanical properties table. Uses the same ISO 180/A method as the PES profile, so the two are directly comparable.
status: ground
source: basf-p3010-nat
where: Mechanical properties table, Izod notched impact strength (23 degC), ISO 180/A
- benchmark: dielectric_strength
label: Electric strength, K20/K20, Ultrason P 3010 NAT
value: 44
unit: kV/mm
scope: material
conditions:
grade: Ultrason P 3010 NAT (unreinforced)
specimen_treatment: K20/K20
method_standard: IEC 60243-1
method: Value as printed in the BASF Ultrason P 3010 NAT product information, Electrical properties table
status: ground
source: basf-p3010-nat
where: Electrical properties table, Electric strength K20/K20, IEC 60243-1
corrosion:
- environment: Ultraviolet light and outdoor weathering
headline: No numeric UV ageing result for PPSU was read in this run. The BASF sheet says UV and water tests were run for outdoor acceptability, but gives no figure.
effect: BASF's P 3010 yellow card footnote f2 says the product was subjected to one or more of UV light, water exposure or immersion under UL 746C, and that outdoor acceptability is for UL to determine. The sheet prints no UV result. The Wikipedia polysulfone article says the family undergoes weathering and that this instability can be offset by adding other materials.
rating: unknown
conditions:
basis: qualitative statements only; no dose, time or property change printed
wavelengths: not stated
source: basf-p3010-nat
where: Yellow card page, footnote f2
- environment: Humid air and immersion in water (23 degC)
headline: PPSU takes up about 1 percent of water at equilibrium.
effect: The Radel R-5000 sheet gives 1.1 percent water absorption at equilibrium (ASTM D570) and 0.37 percent after 24 hours. The BASF P 3010 grade gives 0.6 percent at 23 degC and 50 percent relative humidity, and 1.2 percent in water at 23 degC. The two grades use different test conditions, so the figures are not an exact match.
rating: low
conditions:
humidity: 50 percent relative humidity (P 3010)
immersion: water at 23 degC, equilibrium
method_standard: ASTM D570 (R-5000); similar to ISO 62 (P 3010)
source: radel-r5000-tds
where: Physical table, Water Absorption (24 hr and Equilibrium), ASTM D570
- environment: Long-term heat in air
headline: The UL relative thermal index is 105 degC, which sets the long-term limit for this grade.
effect: The BASF P 3010 yellow card gives a relative thermal index of 105 degC for electrical, impact and strength properties at 1.5 mm, and the HDT is 197 degC at 1.80 MPa. The Radel R-5000 sheet gives 207 degC at 1.8 MPa as a short-term deflection test, not a service-life index. No long-term ageing time is printed for either grade.
rating: moderate
conditions:
basis: UL yellow card relative thermal index, 1.5 mm
short_term: HDT 1.80 MPa (ISO 75 HDT/A and ASTM D648)
source: basf-p3010-nat
where: UL Yellow Card table (RTI Elec, RTI Imp, RTI Str) and Thermal properties table, HDT A
- environment: Steam, sterilising agents and chemicals
headline: The sheet claims resistance to repeated steam sterilisation, acids, bases and detergents.
effect: The Radel R-5000 sheet lists acid resistance, base resistance, chemical resistance, detergent resistance and high environmental stress crack resistance, and it lists steam sterilisation for more than 1000 cycles with morpholine. BASF describes the P 3010 grade as resistant to superheated steam and to stress cracking. Wikipedia says polysulfones resist hydrolysis, aqueous and alkaline media, and that they have low resistance to some solvents. No concentrations or times are given for chemical exposure.
rating: low
conditions:
basis: qualitative feature list and the steam-cycle figure; no chemical concentration or time printed
source: radel-r5000-tds
where: Features list (Acid Resistant, Base Resistant, Chemical Resistant, Detergent Resistant, High ESCR) and Additional Information table
- environment: Gamma and electron-beam radiation
headline: The sheet claims gamma and electron-beam sterilisability, but no dose figure was read.
effect: The Radel R-5000 sheet lists Radiation (Gamma) Resistant, Radiation Sterilizable and E-beam Sterilizable among its features. It prints no absorbed dose, property change or test condition for radiation, so no radiation ageing number is stored.
rating: unknown
conditions:
basis: feature list only
source: radel-r5000-tds
where: Features list
risks:
hazards:
- text: 'Röchling Sustason PPSU safety data sheet (2022): classification None, no signal word, no pictogram and no hazard statements. Particles from cutting or machining are not considered otherwise hazardous, but eye protection is advised.'
ghs: []
source: roechling-sds
where: Section 2 (Hazard Identification) and Section 4 (First-Aid Measures)
- text: The same sheet says the product may contain colour pigments, and it lists carbon black (CAS 1333-86-4) and titanium dioxide (CAS 13463-67-7) under California Proposition 65 as cancer-causing chemicals. The warning applies if one of these is present in the grade supplied.
ghs: []
source: roechling-sds
where: Section 15 (Regulatory Information)
- text: 'BASF''s Ultrason P 3010 NAT product information: proper treatment and reasonable use will not have health-hazardous effects, and no harmful vapours form while processing stays at or below 390 degC.'
ghs: []
source: basf-p3010-nat
where: Product safety section
failure_risks:
- mode: Decomposed melt in the barrel
trigger: Melt above the 390 degC processing limit, or long residence in the barrel
consequence: BASF says decomposed melt can build gas pressure, release violently around the nozzle or hopper, and produce noxious odours. The melt must be purged into the open air and cooled quickly in a water bath, and a hot plasticising unit must not be dismantled.
severity: high
source: basf-p3010-nat
where: Product safety section
- mode: Moisture in the pellets
trigger: Processing without drying
consequence: BASF says the pellets absorb moisture very rapidly and must be dried at least 4 h at 130 to 150 degC before processing. Wet pellets cause defects in moulded parts.
severity: moderate
source: basf-p3010-nat
where: Physical form and storage section
- mode: Dimensional change from water uptake
trigger: Immersion or long exposure to humid air
consequence: Equilibrium water uptake is 1.1 percent (Radel R-5000) and 1.2 percent in water (P 3010), so close-tolerance parts need an allowance for swelling.
severity: low
source: radel-r5000-tds
where: Physical table, Water Absorption
- mode: Long-term heat ageing
trigger: Continuous service near 105 degC
consequence: The UL relative thermal index of 105 degC for the P 3010 grade is the long-term limit printed for this family. The HDT of 207 degC is a short-term test and does not give a service life.
severity: moderate
source: basf-p3010-nat
where: UL Yellow Card table; Thermal properties table
side_effects:
- text: Decomposing melt gives off noxious gases and odours during processing. BASF advises purging into open air and quick cooling in water.
affects: Operators and the processing area
source: basf-p3010-nat
where: Product safety section
- text: In a fire the sheet names CO and CO2 as the special dangers. Major fires need self-contained breathing apparatus and protective equipment.
affects: Responders and the local air
source: roechling-sds
where: Section 5 (Fire-Fighting Measures)
handling:
- text: Dry the pellets at least 4 h at 130 to 150 degC in a vacuum or dry-air drier before processing (BASF). The Radel sheet prints 149 degC for 2.5 h before injection moulding and 171 degC for 4 h before extrusion. Follow the grade's own sheet.
source: basf-p3010-nat
where: Physical form and storage section; Injection and Extrusion tables in the Radel sheet
- text: Pellets can be stored indefinitely in undamaged packaging (BASF). Keep the product away from open flame, since the sheet describes it as combustible.
source: roechling-sds
where: Section 7 (Handling and Storage) and BASF physical form section
- text: Use eye protection when cutting or machining sheet and rod, and use the German MAK dust limits and extraction above the barrel unit.
source: roechling-sds
where: Section 4 (First-Aid Measures) and BASF product safety section
mitigations:
- text: 'Fire: extinguish with water, foam, dry powder or carbon dioxide (Röchling SDS).'
source: roechling-sds
where: Section 5 (Fire-Fighting Measures)
- text: Keep dust concentrations within the German MAK limit and ventilate the barrel unit with an extraction system (BASF).
source: basf-p3010-nat
where: Product safety section
uses:
- application: habitats-and-suits
device: Aircraft cabin interior parts
example: The Radel R-5000 sheet lists FAA FAR 25.853a among its agency ratings. That is the FAA flammability rule for aircraft cabin interior materials. The sheet does not name a part.
source: radel-r5000-tds
where: Features and Uses list, Agency Ratings
- application: habitats-and-suits
device: Surgical instruments and hospital goods, steam sterilised
example: The Radel R-5000 sheet lists surgical instruments, hospital goods, medical devices and ISO 10993, and says the grade passes more than 1000 steam autoclave cycles with morpholine and no cracking.
source: radel-r5000-tds
where: Applications list and Additional Information table, Steam Sterilization with Morpholine
- application: electronics-and-chips
device: Electrical equipment parts
example: Wikipedia says polysulfones are used for electrical equipment, vehicle construction and medical technology. It names no PPSU grade for any of them.
source: wiki-polysulfone
where: Introduction paragraph
supply:
- subject: Sulfur (sulfone-group feedstock for 4,4'-dichlorodiphenyl sulfone)
producers:
- country: China
share_percent: 22.6
year: 2025
- country: United States
share_percent: 9.6
year: 2025
- country: Russia
share_percent: 8.9
year: 2025
- country: Canada
share_percent: 6
year: 2025
critical_lists:
- list: 'USGS 2025 final list of critical minerals (60 minerals): sulfur, sulphur and sulfuric acid are not on it'
listed: false
recycling: The USGS sulfur chapter says 2.5 to 5 million tons of spent sulfuric acid is reclaimed a year from petroleum refining. That is sulfuric acid, not elemental sulfur from polymers.
substitutes:
- 'USGS: substitutes for sulfur at present or anticipated price levels are not satisfactory; some acids may replace sulfuric acid, usually at higher cost.'
source: usgs-mcs2026-sulfur
where: 'World Production and Reserves table, 2025e column (world total 84,000 thousand t; shares calculated by Space Mushroom: China 19,000, United States 8,100, Russia 7,500, Canada 5,000). Critical-list status from usgs-crit2025.'
gaps:
- No atomic oxygen erosion result for PPSU was found. The MISSE and NASA searches returned phenylphosphine oxide polymers and older polysulfone tests, not PPSU.
- 'No numeric UV ageing result for PPSU was read. The Li and co-workers 2022 paper on PES and PPSU microplastics (doi 10.1021/acs.est.1c05812) could not be opened in this run: the ACS page returned 403 and PubMed returned a cookie page.'
- No radiation (gamma or electron) dose or property change for PPSU was found. The Radel sheet only lists the features.
- The 4,4'-biphenol supply was not read. Sulfur is the only feedstock with shares in this profile.
- The atomic weights in the recipe are standard values, not read from a fetched page in this run.
- The Radel R-5000 coefficient of linear thermal expansion and its volume resistivity are printed in exponent notation. Neither is stored, because the checker does not match that value format.
- Tensile impact strength (399 kJ/m2, ASTM D1822) is printed on the Radel sheet but not stored, because no canonical name fits it.
- No media file was checked for this profile. No PPSU photograph or drawing with a licence was read in this run.
- PubChem GHS data for polyphenylsulfone were not read. Hazard entries come from the Röchling SDS and BASF product information.
- The ChemicalBook polysulfone SDS lists hazard statements, but it is a catalogue listing and conflicts with the manufacturer SDS, so it is not used.
- The Röchling SDS prints a melt temperature of 220 degC for a grade that is amorphous. That line is not stored.
sources:
wiki-polysulfone:
title: Polysulfone, Wikipedia (covers PSU, PES and PPSU)
id: Wikipedia article Polysulfone
url: https://en.wikipedia.org/wiki/Polysulfone
year: 2026
kind: web
license: CC BY-SA 4.0
wiki-ppsu:
title: Polyphenylsulfone, Wikipedia
id: Wikipedia article Polyphenylsulfone
url: https://en.wikipedia.org/wiki/Polyphenylsulfone
year: 2026
kind: web
license: CC BY-SA 4.0
radel-r5000-tds:
title: Radel R-5000 Polyphenylsulfone technical data sheet (Syensqo, Form TDS-1445-en, via UL Prospector)
id: TDS-1445-en, document created 30 January 2024, last updated 29 September 2023
url: https://protolabs.com/media/gt1bplki/radel-r-5000.pdf
year: 2024
kind: datasheet
license: supplier document, linked not reproduced
basf-p3010-nat:
title: Ultrason P 3010 NAT product information (BASF SE, PPSU, unreinforced, medium viscosity)
id: BASF Ultrason P 3010 NAT product information, with UL Yellow Card E41871
url: https://download.basf.com/p1/8a8081c57fd4b609017fd6487bac5071/en/ULTRASON%3Csup%3E%C2%AE%3Csup%3E_P3010_NATURAL_Product_Data_Sheet_English.pdf
year: 2026
kind: datasheet
license: manufacturer datasheet, linked not reproduced
roechling-sds:
title: Sustason PPSU Safety Data Sheet (Roechling Industrial Gastonia, version 03)
id: SDS revision 4 January 2022, print date 04.01.2022
url: https://roechling.com/fileadmin/assets/SDS__Sustason%20PPSU_2022.pdf
year: 2022
kind: datasheet
license: supplier document, linked not reproduced
usgs-mcs2026-sulfur:
title: Mineral Commodity Summaries 2026, Sulfur
id: USGS MCS 2026, February 2026
url: https://pubs.usgs.gov/periodicals/mcs2026/mcs2026-sulfur.pdf
year: 2026
kind: report
license: public domain (USGS)
usgs-crit2025:
title: About the 2025 List of Critical Minerals (USGS, final list of 60 minerals)
id: Final 2025 List of Critical Minerals, November 2025
url: https://www.usgs.gov/programs/mineral-resources-program/science/about-2025-list-critical-minerals
year: 2025
kind: web
license: public domain (USGS)
documents:
- title: Radel R-5000 Polyphenylsulfone technical data sheet (Syensqo, TDS-1445-en)
type: datasheet
url: https://protolabs.com/media/gt1bplki/radel-r-5000.pdf
year: 2024
- title: BASF Ultrason P 3010 NAT product information, with UL Yellow Card
type: datasheet
url: https://download.basf.com/p1/8a8081c57fd4b609017fd6487bac5071/en/ULTRASON%3Csup%3E%C2%AE%3Csup%3E_P3010_NATURAL_Product_Data_Sheet_English.pdf
year: 2026
- title: Röchling Sustason PPSU safety data sheet
type: sds
url: https://roechling.com/fileadmin/assets/SDS__Sustason%20PPSU_2022.pdf
year: 2022
- title: USGS Mineral Commodity Summaries 2026, Sulfur
type: report
url: https://pubs.usgs.gov/periodicals/mcs2026/mcs2026-sulfur.pdf
year: 2026
license: CC-BY-4.0
updated: '2026-10-26'
review:
status: draft
method: assistant
checked_values: 27
unreachable: 1
caveats: 5
note: Written by an AI assistant on 2026-10-26 from pages fetched in this run. The BASF P 3010 grade is a different grade from Radel R-5000 and is labelled as such. No UV, radiation or atomic oxygen number for PPSU was found, and the Li 2022 UV paper could not be opened.
story:
recipe:
line: PPSU is made by polycondensation of 4,4'-biphenol with 4,4'-dichlorodiphenyl sulfone, with a base to form the salt and remove the hydrogen halide (Wikipedia names the two monomers). The repeat unit is C24H16O4S, derived by Space Mushroom from those monomers. Wikipedia notes that PPSU has a large amount of biphenyl, which gives it higher heat resistance than PSU, and that it has no isopropylidene group.
parts:
- name: Carbon
symbol: C
atoms: 24
atomic_weight: 12.011
role: Forms the four phenylene rings of each repeat unit, two from the biphenyl and two from the sulfone unit.
- name: Hydrogen
symbol: H
atoms: 16
atomic_weight: 1.008
role: Four hydrogens on each of the four phenylene rings.
- name: Oxygen
symbol: O
atoms: 4
atomic_weight: 15.999
role: Two ether oxygens and the two oxygens of the sulfone group.
- name: Sulfur
symbol: S
atoms: 1
atomic_weight: 32.06
role: Sulfone group, which gives rigidity and heat resistance.
risk_groups:
- title: For people
level: 0
verdict: Not classified hazardous
lead: The Röchling SDS gives no classification, and BASF finds no health-hazardous effects when the product is processed as intended. Dust and hot melt still need care.
points:
- label: The pellets and sheet
line: The SDS lists no hazard statements and no pictograms. It notes that colour pigments may contain carbon black and titanium dioxide, which California lists under Proposition 65.
- label: Dust from machining
line: Eye protection is advised. BASF applies the German MAK dust limit and asks for extraction above the barrel unit.
- label: Hot melt
line: BASF says no harmful vapours form at or below 390 degC. Overheating decomposes the melt and gives off noxious odours.
- title: If the polymer overheats or burns
lead: The SDS says the product is combustible, and in a fire it gives off carbon monoxide and carbon dioxide. Decomposition temperatures printed in this run are the ones the SDS gives for ignition and decomposition.
points:
- label: Gases
line: Major fires need self-contained breathing apparatus and full protective equipment.
- label: Water
line: Water, foam, dry powder or carbon dioxide are the suitable extinguishing media.
- label: Melt in the barrel
line: BASF advises purging decomposed melt into the open air and cooling it quickly in water. Explosions are possible if decomposed melt is not removed.
- title: Handling and storage
points:
- label: Drying
line: Dry the pellets at least 4 h at 130 to 150 degC before processing, because they take up moisture quickly.
- label: Storage
line: Store the pellets in undamaged packaging, away from open flame and high temperatures.
why: Polyphenylsulfone (PPSU) is an amorphous thermoplastic whose backbone carries a biphenyl unit beside its ether and sulfone links. That biphenyl unit separates it from PES. It was chosen for this profile because it is the sulfone polymer that its supplier markets for repeated steam sterilisation, with a deflection temperature of 207 degC at 1.8 MPa and a glass transition of 220 degC on the Radel R-5000 sheet. The same sheet also gives a V-0 flame rating for the transparent grade.
uses:
- where: Aircraft cabin interior parts
line: The Radel R-5000 sheet lists FAA FAR 25.853a among its agency ratings, the flammability rule for aircraft cabin interiors. The sheet does not name a part.
- where: Surgical instruments and hospital goods
line: The Radel R-5000 sheet lists surgical instruments, hospital goods and ISO 10993, and says the grade passes more than 1000 steam autoclave cycles without cracking.
- where: Electrical equipment
line: Wikipedia says polysulfones serve electrical equipment, vehicle construction and medical technology. It gives no PPSU grade for these uses.
can_do:
- label: Heat
benchmark: heat_deflection_temperature
value: 207 degC
line: The Radel R-5000 sheet gives a deflection temperature of 207 degC at 1.8 MPa (ASTM D648, unannealed).
- label: Glass transition
benchmark: glass_transition_temperature
value: 220 degC
line: The Radel R-5000 sheet gives 220 degC by ASTM E1356, and the BASF P 3010 DSC value is also 220 degC.
- label: Stiffness
benchmark: elastic_modulus
value: 2340 MPa
line: The Radel R-5000 sheet gives a tensile modulus of 2340 MPa at 23 degC (ASTM D638, 3.18 mm).
- label: Repeated sterilisation
benchmark: steam_sterilization_cycles
value: More than 1000 cycles
line: The Radel R-5000 sheet says the grade passed more than 1000 steam autoclave cycles at 132 degC with morpholine, without cracking or crazing.
compare: PPSU and PES are both sulfone polymers without the bisphenol-A unit of PSU. PPSU adds a biphenyl unit from 4,4'-biphenol, which Wikipedia links to higher heat resistance. Its datasheets in this run give a glass transition close to PES, and the Radel sheet says its toughness is superior to other high-temperature resins. Its water uptake is reported on ASTM D570 for the R-5000 grade, while the PES profile uses a similar-to-ISO 62 method, so compare the two only after checking the method. The UL relative thermal index for P 3010 is 105 degC, which is lower than the IEC 60216 index in the PES profile. The two indices are different tests and should be read as such.
compare_rows:
- label: Deflection temperature under load
benchmark: heat_deflection_temperature
- label: Glass transition
benchmark: glass_transition_temperature
- label: Tensile modulus
benchmark: elastic_modulus
handling:
- Dry the pellets for at least 4 h at 130 to 150 degC before moulding, because they take up water quickly.
- Keep the material dry, closed and away from open flame.
- Do not overheat the melt above 390 degC, or it will decompose and give off gas.
- Use dust control and extraction, and cool any burnt-off melt with water.
good_for:
- 'Steam sterilisation: the Radel sheet gives more than 1000 cycles with morpholine, and the grade is also labelled for gamma and e-beam sterilisation.'
- 'Flame-rated interiors: the Radel sheet gives a V-0 flammability rating for the transparent grade, and BASF''s P 3010 yellow card gives V-0 at 1.5 mm and 3.0 mm.'
- Parts that must keep their shape near 200 degC under a 1.8 MPa load.
watch_out:
- 'UV and weathering: the family is known to weather, and no PPSU UV number was read. Exposed surfaces need protection.'
- Water uptake of about 1 percent at equilibrium changes dimensions, so close-tolerance parts need allowance.
- The long-term heat limit for the P 3010 grade is a UL relative thermal index of 105 degC, which is well below its 207 degC short-term deflection temperature.
- No atomic oxygen result for PPSU was found, so it is not shown to be space-qualified on the evidence in this profile.
verdict: PPSU is a tough, steam-sterilisable, flame-rated sulfone thermoplastic with well-documented datasheet values. Its long-term heat rating is lower than its deflection temperature suggests, and its UV and atomic oxygen behaviour remain unverified.
References
Every number above carries a reference number. Click one to see the source and where in it the value comes from.
| # | Source | Type | Year | Used for |
|---|---|---|---|---|
| Polysulfone, Wikipedia (covers PSU, PES and PPSU) | web | 2026 | 2 values | |
| Polyphenylsulfone, Wikipedia | web | 2026 | 0 values | |
| Radel R-5000 Polyphenylsulfone technical data sheet (Syensqo, Form TDS-1445-en, via UL Prospector) | datasheet | 2024 | 24 values | |
| Ultrason P 3010 NAT product information (BASF SE, PPSU, unreinforced, medium viscosity) | datasheet | 2026 | 18 values | |
| Sustason PPSU Safety Data Sheet (Roechling Industrial Gastonia, version 03) | datasheet | 2022 | 6 values | |
| Mineral Commodity Summaries 2026, Sulfur | report | 2026 | 1 value | |
| About the 2025 List of Critical Minerals (USGS, final list of 60 minerals) | web | 2025 | 0 values |