Flame Retardant (FR)

Flame Retardant (FR) resins—including UL 94 V-0, V-1, and 5VA-rated modifications of PC, PC/ABS, ABS, and PA66—are critical for electrical and electronic assemblies requiring strict fire safety compliance [1, 2]. However, processing FR polymers introduces serious manufacturing challenges: thermal instability (where FR additives degrade into highly corrosive gases), splay on aesthetic surfaces, and reduced melt flow. At Jucheng Precision, an ISO 9001 and IATF 16949 certified manufacturer, we mitigate these risks using premium corrosion-resistant S136 or M340 stainless mold steels, highly ventilated venting designs, and strict scientific molding temperature windows. We provide a comprehensive, free DFM analysis within 24 hours to prevent air traps and optimize gas venting, ensuring zero-defect electrical parts verified by Zeiss CMM inspection.

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Our available materials

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PA-BASF Ultramid A3EG6

Undergoing continuous thermal degradation and high cyclic loading inside modern engine compartments requires extreme heat-aging resistance, which BASF’s Ultramid A3EG6 delivers through its 30% glass fiber reinforced, heat-stabilized polyamide 66 matrix. Boasting a dry-as-molded (DAM) tensile strength of 175 MPa and a heat deflection temperature (HDT) of 250°C, this high-performance nylon grade is engineered for heavy-duty structural components subject to thermal cycling. At Jucheng Precision, an IATF 16949 and ISO 9001 certified manufacturer, we specialized in high-stress molding of Ultramid A3EG6. Utilizing our in-house five-axis CNC-machined H13 tooling, we mitigate fiber orientation stresses and optimize crystallization, delivering structurally sound parts verified by Zeiss CMM inspection.

PC-SABIC Lexan 940A

Securing reliable structural flammability safety and premium dielectric isolation in complex electronic housings without compromising mechanical drop-toughness requires an elite material, which SABIC’s LEXAN™ 940A delivers through its unreinforced, medium-viscosity flame-retardant polycarbonate matrix. Featuring a density of 1.21 g/cm³ and a glass transition temperature (Tg) of 150°C, this amorphous grade achieves an outstanding UL 94 V-0 flammability rating down to 1.0mm and a 5VA rating at 3.0mm. Jucheng Precision, operating under strict IATF 16949 and ISO 9001 frameworks, specializes in precision injection molding of Lexan 940A. Backed by 35+ advanced presses and in-house five-axis CNC-machined tooling, we control its low isotropic shrinkage (0.5%-0.7%), delivering flawless electrical enclosures verified by Zeiss CMM.

PC/ABS-Covestro Bayblend FR3010

Securing non-halogenated environmental compliance alongside high heat resistance and impact toughness in smart home enclosures and electric vehicle (EV) charging stations requires a specialized amorphous blend, which Covestro’s Bayblend FR3010 delivers. This flame-retardant PC/ABS alloy integrates polycarbonate's structural strength with ABS's easy flowability, achieving an exceptional UL 94 V-0 fire rating at 1.5mm and a 5VA rating at 2.0mm. Jucheng Precision, under IATF 16949 and ISO 9001 frameworks, specializes in precision injection molding of Bayblend FR3010. Utilizing S136 stainless steel molds, we control its low isotropic shrinkage (0.5%-0.7%) and manage volatile gas release, delivering flat, blemish-free electronic covers verified by Zeiss CMM.

Common Flame Retardant (FR) Grades We Mold

We process high-performance halogen-free and eco-compliant Flame Retardant resins from global compounders, meeting strict UL 94 V-0 to 5VA certifications:

FR Material Class	Typical Brand & Grade	Key Characteristics & Advantages
FR-PC/ABS Alloys (Flame Retardant)	• Covestro Bayblend FR3010 • Sabic Cycoloy CY6110 / CY6414	Halogen-free flame retardant with an excellent balance of impact strength, flowability, and dimensional stability. Rated UL 94 V-0 at thin walls. Perfect for charger adapters, battery brackets, and smart meter housings.
FR-PC (Flame Retardant)	• Sabic Lexan 940A / 943A • Teijin Panlite LN-1250G	High-heat flame retardant with glass-like transparency options or opaque structural reinforcement. Exceptional dielectric properties. Applied in power switches, public transit brackets, and optical diffusers.
FR-ABS (Flame Retardant)	• Chi Mei POLYLAC PA-765 / PA-765A • LG ABS AF312	Cost-effective flame retardant with good impact strength, high surface gloss, and easy colorability. Widely used for office copiers, monitor casings, and home appliance housings.
FR-PA66 (Halogen-Free) (Flame Retardant)	• BASF Ultramid A3U42G6 ( Halogen-Free GF) • DuPont Zytel FR50	Environmentally friendly, halogen-free flame retardancy combined with high mechanical stiffness and thermal stability. Crucial for electrical circuit breakers, industrial terminal blocks, and EV fuse boxes.

Applicable Molding Processes for FR Resins

Due to FR resins’ low thermal stability and acidic emissions, specific molding processes must be implemented:

Molding Process	Process Suitability & Application
Standard Injection Molding	Excellent. Highly suitable for molding home appliance enclosures, consumer electronics covers, and terminal block housings.
Thin-Wall Molding	High. Ideal for high-density, thin-walled multi-pin electrical connectors and wall switches with rapid cycle times.
Insert Molding	Excellent. Extensively used in smart grids to encapsulate conductive copper terminals and metal strips directly inside the FR housings.

Flame Retardant (FR) Plastic Molding Technical Guide

Processing FR resins requires strict thermal boundaries and advanced outgassing solutions to protect mold integrity and product aesthetics:

Corrosion-Resistant Steel selection: At high melt temperatures, FR additives degrade, releasing highly corrosive acidic gases (such as halogen or phosphorus acids). Jucheng’s in-house tooling division prevents tool degradation by using high-chromium corrosion-resistant steel (such as S136 or Bohler M340 hardened to 48–52 HRC).
Meticulous Pre-Drying: Wet FR resins are highly susceptible to accelerated thermal degradation, resulting in splay, dark spots, and polymer chain fracturing. We desiccant dry resins at 80°C–120°C (depending on substrate) for 3–4 hours to keep moisture strictly below 0.02%.
Tight Melt Temperature Windows: Melt temperatures must be strictly managed (e.g., keeping FR-PC/ABS below 250°C) and residency time in the barrel minimized to prevent active flame retardant compounds from breaking down.
Highly-Ventilated Venting Design: Outgassing from FR resins can cause dynamic air trapping and diesel burn marks. Our toolmakers machine deep, strategically positioned venting channels (0.015mm to 0.020mm depending on material) on parting lines to secure clean, defect-free parts.

Key Application Industries for Molded FR Components

Electrical Infrastructure & Smart-Grid: Circuit breakers, wall switches, socket frames, relay housings, high-voltage connector housings, and smart electricity meters.
EV Battery Systems & Automotive (IATF 16949): Electric vehicle lithium-ion battery brackets, cell holders, electrical fuse box covers, high-voltage busbar isolators, and wire harness shields.
Consumer Electronics & Telecommunications: Wi-Fi router enclosures, charger adapter bodies, power tool housings, dynamic power supply covers, and set-top boxes.
Office Equipment & Home Appliances: High-end copier housings, desktop printer casings, microwave control frames, and coffee maker structural bases.

Material Properties

Density	1.18 - 1.22 g/cm³
Melt Mass-Flow Rate (MFR) (260°C/5.0kg)	12 - 25 g/10 min
Tensile Strength at Yield	55 - 65 MPa
Flexural Modulus	2,400 - 2,800 MPa
Izod Impact Strength (Notched, 23°C)	400 - 550 J/m
Rockwell Hardness (R-Scale)	110 - 118 -
Flammability Rating (1.5mm - 3.0mm)	UL 94 V-0 Class
Glow Wire Flammability Index (GWFI @ 2.0mm)	960 °C
Heat Deflection Temperature (HDT @ 1.8 MPa)	85 - 95 °C
Linear Mold Shrinkage	0.45 - 0.65 %
Dielectric Strength	22 - 28 kV/mm
Volume Resistivity	1.0E+16 Ohm·cm
Maximum Part Size	1000 x 800 mm
Minimum Part Size	1 x 1 mm