Polysulfone Market Expected to Reach $3.4 Billion by 2031—Allied Market Research

According to a new report published by Allied Market Research, titled, “Polysulfone Market," The polysulfone market was valued at $2.1 billion in 2021, and is estimated to reach $3.4 billion by 2031, growing at a CAGR of 5.1% from 2022 to 2031.

Polysulfone is a family of high-performance thermoplastics known for its toughness and stability at high temperatures. It is a transparent and amorphous polymer with high strength and glass transition temperatures ranging from 180°C to 250 °C. It has a unique combination of properties, including high heat resistance, good dimensional stability, excellent toughness, and resistance to chemicals, making it ideal for use in harsh environments. It is used in healthcare, aerospace, automotive, electronics, and other industries, where its unique properties offer significant advantages over other materials.

Polysulfone belongs to the sulfone polymer family. It is a transparent thermoplastic polymer that has high-temperature resistance, good mechanical properties, and good chemical resistance. It can endure high temperature without deterioration or loss of mechanical properties.

Polysulfone is mostly used in food and beverage processing applications as the wide working temperature range of polysulfone allows components to go from a deep freezer directly to a steam table or microwave oven, and its non-stick surface minimizes food wastage and enables easy cleaning. Moreover, it is used in FDA-recognized devices, medical devices, feeding systems, sterilization trays, hot water applications, and food & beverage processing.

Ultrafiltration membranes made of polysulfone polymer are widely used in the food industry. In addition, polysulfone is used in applications that require high-performance materials, such as aerospace and automotive components, electronic parts, and medical devices. All these factors have escalated the demand for polysulfone. However, polysulfone has a high melting temperature of over 500 °C, making it difficult to process when using traditional methods such as injection molding.

Processing difficulties can raise production costs and limit its use in some applications. Polysulfone has poor weatherability and is prone to degradation due to its sensitivity to UV radiation and moisture. UV radiation can cause the material to discolor and become brittle, while moisture can cause hydrolysis and degradation of the polymer chains, limiting its use in outdoor applications or environments with UV radiation and moisture. All these factors allow consumers to choose alternatives over polysulfone that hamper the market growth.

The COVID-19 pandemic disrupted global supply chains, potentially resulting in raw material shortages and production delays. This resulted in higher polysulfone product costs and longer lead times. Lockdowns and restrictions reduced industrial activity, resulting in a decrease in the production of some materials. This affected the production and demand for polysulfone materials.

On the other hand, the pandemic caused a shift in demand for certain products, with a higher demand for medical devices and personal protective equipment (PPE). Polysulfone is commonly used in the production of medical equipment such as dialysis membranes, blood oxygenators, and other medical devices. As a result, demand for polysulfone in the healthcare industry increases during the pandemic and is expected to remain high in the post-COVID-19 era.

The polysulfone market is segmented into type, grade, application, end-use industry, and region. By type, the market is divided into polyethersulfone (PES), polysulfone (PSU), and polyphenylenesulfone (PPSU). By grade, the market is categorized into food grade, industrial grade, medical grade, and others. By end-use industry, the market is classified into electrical & electronics, consumer goods, transportation & automotive, healthcare, food & beverage, water treatment, sanitary equipment, and others.

In healthcare, it is further fragmented into surgical instruments, dental instruments, hemodialysis, nebulizers, filtration, and others. By application, the market is segregated into membranes, fuel cells, coatings, injection molding, and others. Region-wise, the market is analyzed across North America, Europe, Asia-Pacific, and LAMEA.

By type, the market is categorized into polyethersulfone (PES), polysulfone (PSU), and polyphenylenesulfone (PPSU). Polyethersulfone is used in the filtration industry as hollow fiber membranes and respirator nebulizers due to its excellent filtration properties. PES can endure repeated sterilization, making it suitable for medical appliances, sterilization of electrical equipment, and chemical plants. Its high-temperature resistance allows it to be used in automotive applications such as oil and gas resistance. PES is finding applications as an electrical insulator due to its ability to survive high temperatures for sustained periods.

By grade, the market is categorized into food grade, industrial grade, medical grade, and others. Polysulfone grades include PSU 1000, PSU 1650, and PSU 3180. PSU 1000 is a rigid, high-strength, semi-tough, transparent plastic that outperforms polycarbonate in terms of heat resistance and hydrolytic stability. PSU 1650 and PSU 3180 are two other polysulfone grades with distinct properties. PSU 1650 is a medical-grade polysulfone used in surgical instruments and devices, whereas PSU 3180 is an extrusion-grade polysulfone used in a variety of applications such as electrical components.

By end-use industry, the market is segregated into electrical & electronics, consumer goods, transportation & automotive, healthcare, food & beverage, water treatment, sanitary equipment, and others. The healthcare segment is the fastest growing segment during the forecast period owing to the use of polysulfone in the production of dialysis membranes for blood dialysis machines.

Polysulfone membranes in blood dialysis machines are subject to repeated cycles of cleaning, disinfection, and sterilization to maintain their effectiveness and ensure patient safety. Polysulfone is highly resistant to degradation and can withstand these repeated sterilization cycles without affecting its properties, making it ideal for this application.

By application, the market is fragmented into membranes, fuel cells, coatings, injection molding, and others. Polysulfone is widely used in injection molding owing to its excellent mechanical properties, high strength, stiffness, and dimensional stability. It is used to produce a range of products such as automotive parts, electrical connectors, and medical devices. Injection molding provides a low cost at moderate to large quantities which makes it an ideal process for polysulfone injection molding.

Some of the major companies that operate in the polysulfone market include Asahi Kasei Medical Co., Ltd. , BASF SE, Ensinger, PEXCO, Polymer Industries, RTP Company, SABIC, Solvay S.A., Toray Medical Co., Ltd., Trident Plastics inc.

Key Recent Developments: 

• In 2022, Solvay S.A. expands its U.S. based sulfone polymers business. It helps to focus on polymer solutions for various critical life science applications, as part of its ongoing commitment to build capacity in this field to support a growing global customer base.
• In 2019, BASF SE launched Ultrason P, a new polysulfone-based material for 3D printing. The new material offers high-temperature resistance and excellent mechanical properties, making it suitable for use in automotive, aerospace, and industrial applications.

Key finding of the study

• Asia-Pacific is projected to grow at the highest CAGR of approximately 5.3%, in terms of revenue, during the forecast period.
• By type, the polyethersulfone segment is anticipated to grow with a high CAGR, in terms of revenue, during the forecast period.
• By grade, the medical grade segment is anticipated to grow with CAGR 5.4%, in terms of revenue, during the forecast period.
• By application, the membrane segment is anticipated to grow with high CAGR, in terms of revenue, during the forecast period.
• By end-use industry, the electrical and electronics segment is anticipated to grow with CAGR 5.8%, in terms of revenue, during the forecast period.