Rexolite® Plastic Materials & Machining

Electrical Powerhouse Resin Fit For High Voltage

Although Rexolite® is a form of polystyrene, its cross-linked structure gives it more impact resistance and a harder formation than its unenhanced cousin. Known to withstand high voltages, it makes for an excellent insulator for widespread use in electrical applications. Moreover, most also note the resin's clarity comparable to acrylic when used for optics purposes.

With an above average resistance to radiation, a wide operational temperature range, and a superb sound transmission ability, Rexolite® has many features that can fit products of varying purposes.

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More about Rexolite® Plastic Material & Machining

Key Facts about Rexolite®

  • Excellent insulator
  • Low and stable dielectric constant
  • Low dissipation factor
  • Great thermal stability and mechanical strength
  • Outstanding rigidity and dimensional stability
  • Lightweight
  • Capable of optical grade clarity and transparency
  • Good chemical resistance
  • Excellent sound transmission
  • Low outgassing
  • Low water absorption rate
Rexolite cube with drilled holes
Material Properties Common Applications
RexoliteLightweight, good insulator, optical clarity, chemically resistantAerospace, military, electronics, science, and testing

Properties & Characteristics

Rexolite® is a unique cross-linked polystyrene microwave plastic with several beneficial properties that finds use most often in telecom, aerospace, and (of course) electronics industries. 

With its many unique properties, many engineers know this resin as a strong choice to others like acrylic to serve a more specific purpose. 

Regarding its particular electrical properties, Rexolite® has a dielectric constant of 2.53 (through 500GHz) with extremely low dissipation factors. It maintains incredibly stable electrical properties into gigahertz frequencies. The resin can withstand high voltage exposure, making it also a good insulator for electronic components.

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Compared to standard polystyrene, it has harder, more durable, and somewhat more temperature resistant properties than other materials. It shows these qualities in several different ways. With Rexolite®'s above average resistance to radiation, the resin takes little change in dielectric loss over a wide range of exposures up to 1000M rads. It exhibits superior resistance to mechanical deterioration by ionizing radiation in particular. Rexolite® also has excellent machinability and shock resistance, able to take direct and intense strikes without much loss. However, repeated strikes might result in its eventual fracturing. It also demonstrates its strength via its wide operating temperature range. It can hold its structure to temperatures as low as -270°C (~-455°F) and as high as 176°C (~349°F).  

Furthermore, engineers and designers know Rexolite® as an excellent choice for sound transmission. With low acoustic impedance close to water, this material makes for great sonar lenses among several other applications used for sound. Additionally, it retains structural integrity due to its rigid and durable molecular architecture. It keeps dimensional stability under loads of 10 psi to 2000 psi without structural compromise. The material's lightweight nature also serves as a contributing quality here. With a specific gravity of 1.05, Rexolite® is approximately 15% lighter than acrylic and less than half the weight of Teflon — all this while keeping the previously mentioned qualities. 

Finally, it can withstand exposure to several different types of chemicals. Alkalis, alcohols, aliphatic hydrocarbons, and mineral acids have no effect on the resin's integrity. However, when exposed to aromatic solvents, the chemical does interact and cause structural breakdown. We strongly recommend keeping this material away from those types of chemicals to ensure the product's longevity. 

Common Rexolite® Applications

  • Microwave components
  • Antennae
  • Coaxial cable connectors
  • TV satellite dishes
  • Lenses with acoustic, optical, and radio-frequency applications
  • High-frequency circuit substrates
  • Sonar lenses and radar windows