Sabic’s Innovative Plastics business has launched a new Lexan FST3403 (flame-smoke-toxicity) polycarbonate (PC) copolymer, the first thermoplastic solution for rail seating applications to meet the strictest fire safety requirements under the CEN/TS 45445 standard.

Now commercial a full two years before this European standard goes into effect, new high-performance Lexan FST3403 copolymer – developed specifically for seat back shells and side covers – achieved the highest possible hazard level rating (HL3) under CEN/TS 45445-2 R5. In addition to its exceptional heat release, smoke density and toxicity performance, documented by independent laboratory testing, the new copolymer delivers high flow properties for injection moulding large parts with excellent aesthetics and impact strength.

“Sabic’s proactive focus on developing advanced materials technology for rail industry customers will give them a significant head start in developing compliant seating components for a first-to-market competitive advantage,” said Ilknur Gur, general manager, specialty business in Europe, Innovative Plastics.

“Our new Lexan FST3403 copolymer enables customers to continue using thermoplastics in their seat back shells and side covers instead of having to revert to traditional metal or thermosets that can inhibit design flexibility and potentially add weight and costs from secondary operations. This industry-leading technology greatly simplifies and accelerates compliance with the new European standard.”

The new product was tested by the Currenta Institute in Germany, an independent facility according to the requirements of CEN/TS 45445 2 R5 for seat back shells and side covers. It certified that Lexan FST3403 copolymer complies with the requirements of HL3, the most challenging hazard level to achieve.

The material also provides high flow capabilities that enable large parts, such as seat back shells, to be injection moulded without surface defects. It can also be moulded in tooling that is typically used for PC/acrylonitrile butadiene styrene (ABS) materials. Another aesthetic benefit of Lexan FST3403 copolymer is its ability to be custom coloured.

Lexan FST3403 copolymer provides sufficient impact performance and chemical resistance with protection from wear and tear.