Industrial Polymer Modification
Enhancing Polymer Properties Through Precision Electron Beam Crosslinking
Mercury Plastics provides advanced polymer modification and crosslinking services that help manufacturers strengthen and stabilize their thermoplastic materials. Using high-energy electron beam (e-beam) processing, we precisely control the crosslinking process to deliver consistent, measurable improvements in product performance without chemical additives or harmful byproducts.
What Is Industrial Polymer Modification?
Industrial polymer modification refers to altering the molecular structure of polymers to enhance their physical, thermal, and chemical properties.
Through electron beam crosslinking, high-energy electrons create covalent bonds between polymer chains, converting a thermoplastic into a thermoset structure. The result is a material that resists heat, stress, and chemicals far better than its original form—without residual radiation or chemical crosslinking agents.
Typical improvements include:
Increased tensile and impact strength
Enhanced chemical resistance
Improved dimensional stability
Greater wear, abrasion, and kink resistance
Longer service life and environmental durability
Polymer Crosslinking Applications
Wire & Cable
Crosslinking improves insulation and jacket performance, enhancing temperature, abrasion, and chemical resistance. Ideal for electrical, automotive, and industrial cable where reliability is critical.
Injection Molded Components
Our high-energy beams can process larger or thicker molded parts—something many processors can’t achieve. Used for components requiring improved dimensional stability and thermal performance.
Tubing
Enhances chemical resistance and long-term performance for fluid transfer and industrial tubing applications.
Raw Material Pellets
Pre-crosslinking pellets before molding or extrusion can improve processability, mechanical strength, and creep resistance in the finished part.
Cut Film
Used to strengthen pre-cut shrink film, packaging film, and select medical films, where improved toughness and dimensional control are desired.
About Us
Why Choose Mercury Plastics?
Mercury Plastics delivers a level of technical collaboration and responsiveness that sets us apart in the e-beam processing industry.
Engineering Partnership
From material testing through production, we collaborate to validate and optimize results.
High-Powered Processing
Two high-energy beams (5 MeV and 10 MeV) support a wide range of product geometries and throughputs.
Dual Material Handling Systems
A cart system to handle boxed product and a reel-to-reel system for processing long product lengths.
Reliable Turnaround
Standard lead times of 7–10 working days, versus competitors’ typical 3–4 weeks.
Transparent Pricing
Straightforward cost structure with no hidden fees.
Industrial Polymer Modification FAQs
What is a “dose” in e-beam processing?
In e-beam processing, dose is the amount of energy delivered to a product — measured in kilograys (kGy) or megarads (Mrad). The right dose is critical for achieving optimal crosslink density and performance without over-processing.
Mercury’s in-house engineering team calculates the precise dose mapping for each product and verifies results through testing and process control. Our 5 MeV and 10 MeV beams allow us to handle a wide range of product geometries, wall thicknesses, and material types efficiently and repeatably.
What is a MeV?
MeV (mega-electronvolt) measures the energy of the electrons accelerated by the e-beam. Higher MeV values enable deeper penetration into thicker or denser materials. We maintain two beams (5 MeV and 10 MeV) that support a wide range of product geometries and throughputs.
Does e-beam crosslinking leave residual radiation?
No. The process uses high-energy electrons to create molecular bonds but leaves no residual radioactivity in the product.
What is crosslinked polyethylene (PEX, XPE, or XLPE)?
Cross-linked polyethylene, commonly abbreviated PEX, XPE, or XLPE, is a form of polyethylene that has undergone electron beam crosslinking to improve its structural integrity and thermal performance. Crosslinking increases resistance to heat, pressure, stress cracking, and chemicals, making it ideal for plumbing, wire and cable insulation, heat trace systems, and industrial tubing. Mercury’s precise dosing control ensures consistent, repeatable crosslinking across PEX and other polyethylene-based materials.
What’s the difference between PEX-A, PEX-B, and PEX-C?
All three are types of crosslinked polyethylene, differentiated by how the crosslinking is achieved:
- PEX-A is typically crosslinked using the peroxide (chemical) method.
- PEX-B uses the silane (moisture) method.
- PEX-C is produced using electron beam irradiation (e-beam)—a clean, additive-free process that delivers consistent, uniform crosslinking without chemical residues.
Mercury Plastics specializes in electron beam (PEX-C) crosslinking, offering tight dose control, repeatable results, and short lead times.
How does e-beam crosslinking compare to chemical crosslinking?
E-beam processing achieves the same or higher levels of crosslink density without chemical additives, curing agents, or residual byproducts. It provides better process control, faster turnaround, and a more environmentally friendly result.
Which materials can be crosslinked using e-beam technology?
Typical candidates include polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), ethylene vinyl acetate (EVA), nylon (PA) and various thermoplastic elastomers (TPEs). Each material benefits differently from crosslinking, depending on its molecular structure and intended use.
Can Mercury test my material for crosslinking compatibility?
Yes. Mercury collaborates with clients to test, validate, and optimize the e-beam dose for each specific polymer or product geometry before moving into full-scale production.
E-Beam Crosslinking Resources & Education
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