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.