New resin enables cost-effective metallisation to uplift consumer electronics designs

New ULTEM DT1820EV resin delivers a smooth, high-gloss finish that provides a surface for different decorative aesthetics: paint-free colour, secondary painting or metallisation using physical vapour deposition (PVD). To further improve the appearance, this polyetherimide (PEI) material features surface hardness to help minimise scratches, and high modulus to help avoid PVD layer cracks. Its high flow enables complex, thin-wall geometries that support miniaturisation and weight reduction. Potential applications include camera deco rings, smartphone touch panel frames and smartwatch frames.

“The dynamic consumer electronics market is well known for frequent style changes and fierce competition,” said Scott Fisher, Business Director, ULTEM Resins and Additives, SABIC. “Customers are always looking for new materials that can provide a distinctive, high-quality appearance at a reasonable cost. To address this need, we developed ULTEM DT1820EV resin. It uplevels component design without the high costs of using traditional materials like metal. By adopting the new ULTEM grade using PVD, our customers can achieve stunning aesthetics while benefiting from the practical design and manufacturing advantages of a thermoplastic.”

Colourful metallisation with PVD

SABIC’s ULTEM DT1820EV resin is well suited for direct sputtering PVD metallisation. During sputtering, the material’s high heat resistance and primer-less adhesion to the PVD layer enable faster throughput. In addition, its stiffness and low coefficient of thermal expansion (CTE) help to avoid cracks in the metallised layer. Using PVD with ULTEM DT1820EV resin yields a colourful, and glossy finish that replicates the look of metal while lowering the overall production costs.

Further, PVD is a simpler process than nonconductive vacuum metallisation (NCVM), which is typically used for glass-filled polycarbonate (PC) resin. For example, the PVD layer, which determines the colour of the part, enables the elimination of three coating steps used in NCVM. The thick coating that results from NCVM can accumulate along the edges and corners of the part, preventing a clean, sharp line.

“Building on ULTEM resin’s 40 years of achievements, SABIC has developed another innovative material solution that combines beautiful aesthetics with practical advantages,” said Meredith Ji, Sr. Scientist, ULTEM Resins and Additives, SABIC. “Our new grade, which is compatible with PVD, offers consumer electronics designers new opportunities to emulate metal. But we didn’t stop there. This new grade delivers key performance properties requested by device makers, including UV and chemical resistance. New ULTEM DT1820EV resin is carrying on our proud tradition of customer-centric innovation. To help customers meet their net-zero goals, ULTEM DT1820EV resin will also be available in an ISCC+ certified renewable version.”

SABIC’s new ULTEM DT1820EV resin is globally available.