How Additives Improve Processability & Surface Properties of Thermoplastic Compounds (With Formulating Tips)

Thermoplastic compounds require a specific performance balance: they must be efficient to extrude, mold, and convert, while also meeting strict end-use specifications for visual aesthetics, haptic feedback, tribological behavior, and surface functionality.

Achieving this balance depends on polymer compatibility, additive chemistry, carrier resin selection, and loading levels. At SILIKE, we engineer and manufacture silicone-based additives that simultaneously address specific processing bottlenecks and surface property requirements.

Optimizing Processability During Conversion
During extrusion, injection molding, blow molding, or film production, a thermoplastic melt is subjected to high shear stress, elevated temperatures, and metal-to-polymer friction. Properly selected processing aids effectively manage these parameters.

♦ Lower Melt Viscosity & Improve Flow: Internal lubricants and compatible modifier systems increase melt mobility. This facilitates consistent mold filling, stabilizes extrusion profiles, and measurably reduces extruder torque and die pressure.

♦ Mitigate Melt Fracture (Sharkskin): At critical shear rates—particularly in polyolefin film, pipe, and profile extrusion—polymer melts can exhibit flow instabilities leading to melt fracture. Appropriate processing aids alter the flow dynamics at the die wall, mitigating surface roughness and sharkskin defects.

♦ Minimize Die Build-up (Drool): Accumulation of degraded polymer, pigments, or fillers at the die lip disrupts continuous production. Formulating with tailored additive packages minimizes die deposits, maintaining dimensional stability and maximizing equipment uptime.

♦ Enhance Dispersion: In highly filled compounds, additives promote the homogeneous distribution of mineral fillers, pigments, or functional particulates. Optimized dispersion yields uniform rheological behavior and consistent mechanical properties.

♦ Improve Production Efficiency: By stabilizing melt flow and reducing internal/external friction, processors can optimize line speeds and cycle times without compromising the mechanical integrity of the finished part.

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Modifying Surface Properties Without Secondary Operations

Functional additives are formulated to migrate or concentrate at the polymer-air interface during the cooling phase. This mechanism modifies the surface characteristics of the finished component, eliminating the need for secondary coating operations.

Typical additive approaches for specific surface parameters include:

Surface Parameter Functional Result in Finished Compound
Lower Coefficient of Friction (COF) Reduced sliding friction, optimized conveying, decreased surface drag
Scratch & Mar Resistance Minimized visual scuffing, sustained surface integrity under mechanical stress
Optimized Haptic Properties Controlled tactile feedback (e.g., reduced tackiness, silky/dry touch)
Gloss Control / Surface Finish Mitigation of flow marks, reduction in surface roughness (Ra)
Anti-block Performance Decreased adhesion forces between film layers or stacked molded parts

The SILIKE Silicone Masterbatch Mechanism

For compounding PP, PE, TPE, TPU, and various engineering plastics, a silicone masterbatch is frequently specified to integrate processing efficiency with long-term surface modification.

By utilizing ultra-high molecular weight (UHMW) siloxane polymers dispersed in specific carrier resins, SILIKE Masterbatches function through a dual-mechanism:

1. Rheological Modification (Internal): Reduces internal intermolecular friction and external polymer-to-metal friction, lowering torque and preventing flow-induced surface defects during extrusion or molding.

2. Surface Modification (External): Decreases the static and kinetic coefficient of friction (COF), improves scratch and abrasion resistance, and provides a specific tactile finish on the final part.

Application Case: In PP/TPO/TPV automotive interior components—such as door panels, dashboards, center consoles, and instrument panels, including highly filled PP/talc systems—SILIKE Anti-scratch Silicone Masterbatch features enhanced matrix compatibility with polypropylene resins (CO-PP/HO-PP). This minimizes phase segregation and prevents additive exudation, thereby reducing fogging, VOC emissions, and odor without generating surface stickiness. At a dosage of 1.5–3%, it enables PP/TPO systems to meet stringent OEM scratch testing standards, such as VW PV3952 and GM GMW14688 (achieving a color change of ΔL < 1.5 under a 10 N load), while delivering long-lasting scratch protection, reduced dust buildup, improved surface aging resistance, and supporting a consistent haptic finish across the molded component.

Selecting the Right SILIKE Solution

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A successful thermoplastic additive solution requires matching the specific processing challenge with the correct polymer chemistry. SILIKE provides targeted plastics additive technologies engineered for specific thermoplastic requirements.

Processing / Performance Challenge Recommended SILIKE Solution Key Functional Mechanism
Improve processing & Surface Enhancement Silicone Masterbatch UHMW siloxane dispersion provides efficient internal and external lubrication, optimizing processing performance and surface properties. It improves melt flow, reduces processing torque, die pressure, and energy consumption, while enhancing mold release and productivity. At the same time, it reduces friction, improves scratch and wear resistance, and provides better slip performance and surface feel.
Scratch Resistance Improvement Anti-scratch Silicone-based Masterbatch Silicone-based surface modification enhances surface lubricity, reduces friction-induced damage, and improves scratch resistance
Abrasion Resistance Improvement Anti-abrasion Silicone Masterbatch UHMW silicone polymer migration forms a lubricating layer, reducing frictional wear and improving durability
Soft-Touch & Elastomer Modification Si-TPV Dynamic vulcanized silicone rubber phase provides elastic recovery, soft touch, and long-lasting tactile performance
Extrusion Stability & Melt Processing SILIMER PFAS-Free PPA Reduction of melt-wall friction improves flow stability, reduces melt fracture, and die build-up

Formulation Variables and Regulatory Compliance

Modifying one compound property can inadvertently impact others. Formulation development requires a systematic evaluation of matrix compatibility, surface-energy requirements, and regulatory specifications.

As global regulatory frameworks—such as the EU’s Packaging and Packaging Waste Regulation (PPWR) and impending global PFAS restrictions—evolve, polymer manufacturers require verified material data to support their transition toward more sustainable processing.

As processors actively seek fluorine-free alternatives to maintain extrusion efficiency, our SILIMER PFAS-Free PPA series provides a highly functional and safe solution. Designed to perform without fluoropolymers, it serves as a reliable alternative for polymer manufacturers transitioning away from traditional fluorinated processing aids while maintaining excellent surface quality and stable output.

Conclusion

Optimizing thermoplastic processability and surface characteristics is most efficiently achieved through the integration of multifunctional, polymer-compatible additive systems.

At SILIKE, our siloxane-based polymer processing aids technology and targeted surface modifier solutions provide compounders and processors with measurable improvements in both manufacturing efficiency and end-use component performance.

For technical inquiries, TDS requests, and material evaluation, contact Amy way.

Phone: +86-28-83625089
Email:sale@levvymetal.com
Website:www.siliketech.com

Powder Coat Booths

For those larger-sized parts, or smaller quantity runs, we have 2 independent powder coat booths and ovens. The quality, durability and affordability of today’s powder coating finishes make this the process of choice for world-class companies.

Powder coating advantages over other forms of coating are many. Materials used in the Powder coating process can be metals and non-metals that come in a multitude of thicknesses, textures, colors, etc. Another of Powder coating’s biggest advantages over conventional coatings is its ability to create finishes in many different textures. Powder Coating Booths allow us the ability to apply these advantages to large products.

Wet Paint Line

Tri-State Fabricators runs a full-service conveyor line for painting. Wet painting can provide protection or decoration to many different part styles. From start to finish, every project is easier to undergo random and point-based inspection by our skilled painting team.

Advantages to our Wet Paint Line are these lines start with product prep and ends with a thorough inspection of a high quality finished product. Our ability to complete large and small projects with a superior finish and doing so in a timely and economical fashion. This passes along the savings in production to our customers. When powder coating ins not an option, our Wet Paint Line gets the job done right the first time.

Wet Paint Booths

When the parts get big and heavy we roll-out our custom paint racks and oversize booth. By utilizing our partnerships with all the major paint brands, we can match virtually any color with wet paint.

The advantages of having access to a Wet Paint Booth are many. Large projects of many different shapes can be loaded into the booth. The Wet Paint Booth offers an environment that is much more controlled than a typical parts painting operation.

Not only are they used because of their controlled environment, but they’re are also advantageous when it comes to applying paint to parts that are needed in industries that require specialty coatings such as medical, aerospace, etc.

Military CARC

Our military forces have some very high standards when it comes to the finish of their vehicles and equipment. From the first pre-treatment step to final coat, it takes a great deal of knowledge and experience to protect the men and women of our armed forces. They deserve only the best, and Tri-State Fabricators provides it.

All of our processes are closely monitored by our staff and management teams. Both of which are highly trained in the processes of metal fabrication and finishing. Tri-State Fabricators’ goal is to always fully satisfy each and every customer, including the military. We will always put a 110% into what we do.

Glass-Bead Blasting

Abrasive media blasting is an excellent way to remove old paint, rust, and increase the paint/powder adhesion. Glass beads produce a much smoother and brighter finish than angular abrasives; leaving the part clean yet without any dimensional change. Chemically inert and environmentally friendly, we can recycle our beads approximately 30 times; making them a more preferred method of metal cleaning or surface finishing.

Advantages to Glass Bead Blasting are many. Glass bead blast media is used when a project is needing rough surfaces need to become smooth for applications of coatings such as paint. It is typically used to clean paint and rust from a product surface without deforming the surface it is being used on. Overall, compared to many other blasting media, Glass Bead Blasting is a very economical choice and those savings are always passed on to our customers.

Part Washing

Tri-State Fabricators utilize a zinc phosphate wash to clean and etch the material to ensure the best paint adhesion possible. The unique design of our 3-stage wash system does the work like a 5-stage. From Cleaning and rinsing to conversion coating and post-treatment, Our Part Washing process is a complete service and works throughout the fabrication service and the finishing service.

Along with the previously mentioned benefits, Curing is a vital chemical reaction that leaves the product finish hard and relatively safe from mild abrasion and aggressive corrosion. This process can be done in more than one way; ambient air-dry or in curing ovens at temps that exceed 240°.

Burn-Off Oven

From fixing paint mistakes (someone else’s of course) to simply cleaning our paint line hooks, our burn-off oven is put to good use. After a quick burn-off, a little clean up, and a fresh coat of paint, your parts will look better than new.

Why does our Burn-Off Oven work so well? Because super heating the air around parts turns the materials into ashes. From paint and powder coatings to rubber and machining oils, high temps do the job without degrading the integrity of the part.

Masking

Masking is a vital part of producing high quality products. We have die-cut masking patterns to protect machined surfaces as well as a wide range of plugs and caps to protect threaded holes and bolts. We provide permanent and temporary masking.

Masking allows the selected sections of a product to be protected from a fabrication or finishing service. This can be with both chemicals when etching and tapes, paints when only finishing just a section of the product. Masking is great in aiding the customization process of a project.

Screen Printing

Screen printing is a photographic process that transfers artwork onto a porous nylon screen which allows colored ink to flow through the screen and be deposited on an aluminum or plastic component. We can generally have just about any design created onto a screen for your parts.

Some of the advantages of Screen Printing are, brand recognition for your business displaying on your products, assembly instructions, product warnings/hazards, etc. Tri-State Fabricators produces Screen Printing of the highest quality so you know it’s durable.

Metal Finishing

Metal Finishing is the art of treating the exterior portion of product, often metal but can also be made of other materials, so that the surface is clean and free of any debris. Then the process of applying coats or either paint of powder coat takes place. This coating process improves the quality of the product in both appearance and resistance to wear and corrosion.

Tri-State Fabricators, Inc., understands that a project typically isn’t complete until a high-quality finish has been added to your product. This is why our painting and powder coating teams continuously inspect the products throughout the Metal Finishing process.