Polytetrafluoroethylene (PTFE) composite materials, such as those used in high-performance laminates like RT-duroid®, offer exceptional properties for electronic applications. However, their unique chemical composition and processing requirements necessitate adherence to specific safety guidelines.

1. General Safety Precautions

• Avoid Overheating:
  • PTFE decomposes at temperatures above 260°C (500°F) and releases toxic fumes, including perfluoroisobutene (PFIB) and hydrogen fluoride (HF).
  • Ensure proper ventilation during high-temperature processes like soldering or thermal pressing.
• Minimize Dust Generation:
  • Machining, drilling, or sanding PTFE can generate fine dust that may cause respiratory irritation if inhaled.
  • Use appropriate dust collection systems and personal protective equipment (PPE).
• Avoid Open Flames:
  • PTFE is non-flammable under normal conditions but can degrade and release hazardous fumes when exposed to direct flames.

2. Handling Guidelines

• Wear Protective Equipment:
  • Gloves, safety glasses, and long-sleeved clothing to minimize skin contact and potential irritation.
  • Respiratory protection if working in environments with dust or fumes.
• Storage:
  • Store PTFE composite materials in a cool, dry place away from direct sunlight, high temperatures, or chemicals that may react with PTFE.

3. Processing Safety

• Machining:
  • Use slow spindle speeds and sharp carbide tools to prevent overheating and reduce dust generation.
  • Maintain good ventilation or use localized fume extraction.
• Etching and Cleaning:
  • If chemical etching is required for surface preparation, follow the chemical manufacturer’s safety data sheets (SDS) for handling acids or solvents.
• Thermal Processing:
  • Use temperature-controlled equipment to avoid accidental overheating.
  • Preheat laminates to avoid thermal shock during soldering or lamination.

4. Environmental Considerations

• Disposal:
  • PTFE waste should be disposed of in compliance with local regulations.
  • Avoid burning PTFE, as it produces hazardous gases.
• Outgassing:
  • PTFE has low outgassing properties, making it suitable for aerospace and cleanroom environments, but any decomposition products in vacuum or high-heat environments should be monitored.

5. First Aid Measures

• Inhalation of Fumes:
  • Move the person to fresh air immediately.
  • Seek medical attention if symptoms such as coughing, difficulty breathing, or irritation persist.
• Skin Contact:
  • Wash with soap and water to remove PTFE dust or residues.
  • Consult a doctor if skin irritation occurs.
• Eye Contact:
  • Rinse eyes thoroughly with clean water for at least 15 minutes.
  • Seek medical attention if irritation continues.
• Exposure to Decomposition Products:
  • Treat as a chemical exposure: evacuate the area, provide ventilation, and seek medical advice immediately.

6. Regulatory Compliance

• Ensure all handling and processing activities comply with local occupational health and safety regulations.
• Follow guidelines outlined in the manufacturer’s Safety Data Sheet (SDS) for the specific PTFE composite material.

7. Emergency Preparedness

• Fire Response:
  • Use CO₂, foam, or dry chemical extinguishers for fires near PTFE materials.
  • Avoid water streams, which may spread molten material.
• Spill Control:
  • Sweep up PTFE dust using wet methods to minimize airborne particles.
  • Dispose of waste materials in sealed containers.

8. Training and Awareness

• Train all personnel on the potential hazards of PTFE materials and proper safety protocols.
• Provide access to SDS documents and ensure clear labeling of PTFE materials and associated chemicals.

PTFE composite materials like RT-duroid® are versatile and reliable but require careful handling to ensure safety during processing and use. By adhering to these safety guidelines, you can minimize health risks and maintain a safe working environment.