Custom polymer manufacturing is used in many industries and for many products. We have the ability to start creating your polymers from scratch, or we can use deformulation and reformulation to re-create the polymers you need for your applications. This process depends on a few variables: required volume, which determines where your products will be manufactured commercially, and whether you start with a control sample to be matched, or you require a novel polymer from scratch.
Custom Polymer Manufacturing Process
Concept
There are a few ways we can start the custom polymer manufacturing process, usually, the first step is to sign an NDA, which allows for the full exchange of confidential information. Then work can begin on designing a solution based on your requirements. One method of development is through matching a control sample which you can provide. During this conception phase, we will discuss deformulation, which allows us to determine the exact makeup of the polymer. To learn more about the process, check out our blog on deformulation.
Another type of polymer synthesis project creates a new polymer without a standard control material. In this case, we will determine the desired makeup of your polymer and the characteristics you are looking for, including the chemistry, molecular weight, and manufacturing process. Some of these properties you may already know, however, we will help you fill in the gaps.
In the Lab
When a control sample is available, it will be sent out for testing, including NMR, FTIR, pyrolysis GCIS, GPC, and more to determine the exact makeup. We can also measure the important physical properties of the sample. Our team will then use this data to reformulate the polymer in the lab starting from available monomers and developing a reaction process.
After initial formulating and procedure development, we can then begin the lab synthesis of the targeted product. We test for initial properties and determine where the polymer falls short so we can make adjustments to improve the polymer. This process continues until the target polymer has the properties needed for your application. Our analytical testing will compare your reformulated polymer to the control to ensure consistent chemical makeup, molecular weight, and other required performance properties. The is then sent to you for testing and approval.
Production
Production can begin once lab testing is complete and your polymer has all of the properties you desire. Depending on the required volume, National Polymer may be able to produce it in-house, or we will work with a reliable manufacturer to get you the high-volume, high-quality polymers you need.
When You Need Custom Polymer Manufacturing, Turn to National Polymer
At National Polymer, we are able to deformulate down to monomer levels to get the greatest level of detail possible. Our team also has the knowledge of polymer synthesis and processing to translate these results into commercial success. These two capabilities alone give us a better starting position than many other custom polymer manufacturers out there.
Our team has decades of experience in polymer synthesis and we have knowledge of a wide range of polymer characters. This allows us to better serve and understand our customers’ needs and the requirements of their applications. We are able to match each customer with the polymer that is right for them.
We also have the manufacturing capabilities needed to create high quality, workable samples within our lab. This gives you an idea of what your products or parts will look like and how they will function before you invest in full-scale production, saving you time and money in the long run.
Plus, we have experience in a wide range of industries. From architecture to electronics to medical and more, we are able to serve nearly any industry out there. We will simply consider your needs, and get the job done so you have the best polymer product for your applications.
Reach Out Today to Get Started on Your Custom Polymer Manufacturing Project
If you are ready to get started on your custom polymer manufacturing project, contact our team today.
