Polysulfone Plastic Material & Machining

Stable & creep resistant material ideal for medical components

Play Video

Polysulfone comes as a transparent and stable plastic. An amorphous polymer, polysulfone contains repeating molecules of sulfur throughout its backbone. This structure lends the material intense strength, flame resistance, and dimensional stability despite high temperatures.

Polysulfone resists creep, steam, and chemicals. Due to these resistances, it remains a popular material for plastic parts in the aerospace, automotive, medical, and life sciences industries. This FDA-approved material often compares better than polycarbonate for applications requiring steam sterilization and high temperatures. This is why more in those industries elect to use this material for assorted components.

Is Polysulfone a fit your project?

Reach out today for a free, no obligation quote!

Grade Product Characteristics Common Applications
PolysulfoneGreat stability, creep resistant, great steam resistanceMedical research components, aerospace components, life science applications

More About Polysulfone Plastic Material & Machining

Key Facts About Polysulfone

  • Dimensionally stable
  • FDA approved grades available
  • Sterilizable and biocompatible
  • UV resistant grades available
  • Low outgassing
  • Excellent thermal stability
  • High tensile strength; known for toughness and ability to resist deformation and creep under loads
  • High chemical resistance
  • Excellent electrical insulation
  • Flame resistant

Properties & Characteristics

Polysulfone manifolds and machined parts remain tough and stable while resisting creep and deformation in harsh and aggressive environments. Known for its high tensile strength (with a flexural modulus), these qualities remain steady even as surrounding temperatures increase. Polysulfone can withstand elevated temperatures up to 185°C (365°F) and still retain its dimensional stability -- even for prolonged periods.

Additionally, when it comes to chemical resistance, this material demonstrates outstanding performance. It has a high resistance to many types of chemicals, particularly bases, bleach, and salts. Polysulfone plastic parts hold up when also exposed to soap, detergent solutions, and some hydrocarbon oils under moderate stress levels. With these resistances as well as its resistance to hydrolysis, many choose this material when the end product will undergo repeated steam sterilization and hot water cleaning methods throughout its lifetime.


Regarding electrical properties and flammability, this material exhibits some strong qualities. Its dielectric strength makes a great choice for electrical insulation as it's less likely to ignite from electrical influences. In that vein, polysulfone has a high limiting oxygen index (LOI) due to its molecular structure. In the rare event that it ignites, it self-extinguishes once removed from an ignition source.

Aesthetics, Processing, & Applications

When it comes to aesthetics, polysulfone comes as a light amber material which is readily polished and bonded to other materials. Although that is the only color, it arrives already transparent for applications needing that quality. With polishing, it can become optically clear for uses requiring that quality.

This material also has flexible and versatile qualities that make it easier for manufacturing and machining. Used in different methods like thermoforming and extrusion, manufacturers can use the material in a wide variety of components, manifolds, and parts.

Ready to get your project started?

Reach out today for a free, no obligation quote!

Polysulfone Polishing

Polished polysulfone is often used in hot water applications due to its higher continuous service temperature. In addition, polysulfone resists water absorption and can tolerate steam sterilization to 140°C (285°F). This material resists radiation sterilization particularly well, and designers often use clear polysulfone components in FDA-compliant devices.

To increase clarity, designers choose either vapor polishing or optical machining. As effective approaches to this end, clear polysulfone components allow for easy inspection for quality qualifying purposes.


  • Aerospace components
  • Automotive components
  • Medical research devices
  • Life science applications