In recent years, high-performance thermally conductive compounds have found increasing use in applications where efficient heat management is required, without sacrificing the lightness, design freedom, and manufacturability typical of thermoplastic materials.

After a decade of development and industrial consolidation, these materials are now present in the catalogs of major technical compound manufacturers, with specific grades designed for injection molding of high-performance components in electronic, automotive, industrial, and HVAC applications.

However, the adoption of thermally conductive compounds requires a different design approach compared to conventional metallic materials such as aluminum or copper. Numerous myths and technical misunderstandings still persist that can compromise the effectiveness of proposed solutions.

Main Errors to Avoid when Choosing a Thermally Conductive Compound

Error 1: Expecting Performance Identical to Metals

One of the most common beliefs is that a thermoplastic compound with high thermal conductivity should offer the same heat transfer performance as metals.

This expectation is unfounded: real applications have demonstrated that, in most cases, metals are oversized and that good design allows similar results to be achieved even with materials having ten times lower conductivity.

This is particularly true in systems operating in natural convection, where heat is dissipated without forced ventilation. In these cases, the performance difference between metal and compound is drastically reduced when supported by adequate design.

Error 2: Maintaining Non-Optimized “Metal-Based” Geometries

A second frequent error is replicating geometries designed for metal, for example in heat sinks, without adapting them to the characteristics of thermoplastic compounds.

Due to the composite and anisotropic structure of filled materials (typically with fibers, graphite, or ceramic fillers), it is essential to redesign the component to optimize thermal flow and mechanical integrity, introducing elements such as:

• reinforcement ribs
• variable thicknesses
• wide fillets to reduce stress
• FEM optimization for fiber orientation

Understanding and Exploiting the Properties of Thermally Conductive Compounds

Anisotropy and Conscious Design

Thermally conductive thermoplastic compounds are not homogeneous: their anisotropic structure implies different thermal conduction and mechanical behavior depending on material orientation during molding.

Understanding this aspect is fundamental to avoid errors in the design phase and obtain reliable results. Ignoring anisotropy means risking deformations, poor thermal efficiency, or even premature failures.

More than Thermal: Mechanical, Aesthetic, and Electrical Properties

Beyond thermal performance, these compounds offer multiple properties, including:

• stiffness and mechanical strength comparable to structural grades
• flame retardancy for electrical or HVAC applications
• electrical resistance or electrical conductivity, if required
• good dimensional stability even with high-density fillers
• possibility of coloring or surface finishes for aesthetic requirements

These characteristics make them multifunctional solutions, suitable for replacing metal components even in complex or regulated environments (e.g., electronic equipment, LEDs, battery chargers, electrical panels, pumps, electric motors).

Sectors where Thermally Conductive Compounds are Establishing Themselves

Key applications include:

Guidelines for Effective Design

To make the best use of a high-performance thermally conductive compound, it is advisable to:

1. Precisely define thermal requirements and simulate heat flow (CAE/FEM).
2. Choose the correct material based on matrix (PA6, PPA, PPS, PEI…) and filler (graphite, boron nitride, alumina…).
3. Integrate mechanical and dissipative functions in the same component, where possible.
4. Collaborate with the compound supplier to identify the best grade based on geometry, process, and quantity.

Conclusion: a Growing Opportunity for Industrial Design

High-performance thermally conductive compounds are not simple economic alternatives to metals: they represent a new class of materials for lighter, integrated, and sustainable designs.

Adopting them requires a design paradigm shift, but the potential is extensive. The growing attention to energy efficiency and sustainability makes their adoption increasingly strategic.

FAQ – Frequently Asked Questions about Thermally Conductive Compounds

1. What is the difference between a thermally conductive compound and a metal in thermal dissipation?
   A compound has lower conductivity, but can be optimized in terms of shape and design to compensate. Additionally, it is lighter and more workable.
2. When is it convenient to use a thermoplastic compound instead of aluminum?
   When you want to integrate multiple functions (thermal, mechanical, aesthetic), reduce weight and complexity, or avoid post-molding operations.
3. Are thermally conductive compounds recyclable?
   Yes, being thermoplastic, they can be reprocessed, unlike thermosets. However, the degree of recyclability depends on the type of filler and the purity of the return flow.

Contact Us

If you are designing components for applications requiring advanced thermal management, you might consider introducing a high-performance thermally conductive compound. A preliminary analysis with your supplier or technical partner can help you avoid errors and optimize the production cycle. Contact us here.