UV radiation is one of the most powerful forces that outdoor equipment and components face. Fading finishes and yellowing plastic are easy to see on the surface. However, UV damage penetrates materials at the molecular level, breaking polymer chains through photodegradation.
Choosing UV-resistant plastic, foam, and other materials is the first step towards making your outdoor components more durable. But that’s only part of the picture. Your design choices can also protect flexible materials from UV exposure and prevent premature failure.
Effects of UV Degradation on Flexible Materials
UV radiation weakens chemical bonds, causing materials to crack, become brittle, and fade. Over time, they lose their strength, elasticity, and shape, resulting in decreased performance. Material failures can include:
- A seal that loses its flexibility and begins to leak.
- A gasket that cracks, compromising a weatherproof enclosure.
- A foam pad that disintegrates and loses its cushioning function.
- Color-coded markings that fade and become unidentifiable.
For instance, in telecommunications enclosures, a cracked gasket doesn’t just look bad. It invites moisture that shorts out thousands of dollars in circuitry.
How to Design Components to Minimize UV Damage
While you can’t completely prevent UV degradation, you can mitigate the effects of UV radiation through your design and material choices.
Material selection:
- Choose UV-stable materials such as BISCO® silicone, acrylic, or EPDM.
- Consider UV-resistant coatings for materials with less stability.
Geometry and shielding:
- Design enclosures or housings to protect plastic from UV through shrouding or shadowing.
- Orient UV-sensitive surfaces so that they face inwards or away from direct sunlight.
- Use overlapping layers to protect gaskets and seals.
Designing for replacability:
- Make UV-exposed components modular, so they are easy to replace.
- Plan maintenance intervals based on expected UV exposure.
Putting Your Design to the Test
Even the best material selection benefits from validation before you commit to full production. Building a prototype and testing it under conditions your component will actually face provides valuable insight that a datasheet can’t.
Depending on your time and resources, you can test prototypes in the field or with accelerated weathering tests. An ASTM-certified lab typically performs these tests. These labs simulate extended sun exposure by cycling the sample through controlled UV light, heat, and moisture. The output indicates whether your component retains its properties under sustained UV stress.
American Flexible Products offers fast, custom prototyping services so you can validate your design and its performance in real-world conditions. If you’re unsure where to start with prototyping or testing, AFP’s engineers can point you in the right direction. Contact our team to get started.
Ready to Design for the Outdoors?
The best time to think about UV performance is before the first part is cut. Whether you’re designing a new product or re-evaluating an existing one, AFP’s engineering team can help you choose materials and plan for the environments your product will actually face. Contact us to discuss your application and material needs.
