plasticsmetals

Plasticsmetals refers to materials that combine plastic polymers with metallic components to achieve properties beyond those of ordinary plastics or metals. The term encompasses metal–polymer composites, polymer-coated metals, and polymer matrices with dispersed metal particles. Common configurations include metal particles or fibers embedded in a thermoplastic or thermosetting resin, and partial or fully metal networks within a polymer matrix. Manufacturing methods include blending metal powders with polymers, in-situ metal deposition onto polymer surfaces, extrusion or injection molding with metal fillers, and post-processing steps such as debinding and sintering for highly metal-rich filaments used in additive manufacturing.

Properties of plasticsmetals depend on composition and structure. Metal fillers can impart electrical and thermal conductivity, while the polymer matrix provides ductility, impact resistance, and corrosion protection. Percolation thresholds determine when a conductive network forms, influencing electromagnetic shielding, sensor technologies, and heat management. Mechanical properties such as stiffness and strength-to-weight ratio can be tailored by adjusting metal content and particle shape. The materials also offer potential for improved wear resistance and damping, as well as design flexibility through complex geometries achievable by polymer processing techniques.

Applications span electronics, automotive and aerospace components, consumer electronics housings, heat exchangers, connectors, and EMI shielding parts. Challenges include achieving uniform dispersion and strong adhesion between metal and polymer phases, managing thermal expansion mismatch, processing costs, recyclability, and controlling porosity and residual stresses. Ongoing research focuses on surface treatments, coupling agents, nanoscale metal fillers, and hybrid architectures to enhance performance and broaden processing options.