1. Flame Retardant Regulations Introduction

Flame retardancy is not a “nice to have” for many engineering plastics – it is a legal and safety requirement. Electrical and electronic (E&E) components, automotive parts, and aerospace interiors must resist ignition, self‑extinguish quickly, and produce low smoke and toxicity in the event of a fire. Failure to comply can lead to product recalls, liability lawsuits, and barriers to market access.

However, the regulatory landscape is complex. Different regions have different standards (UL94 in North America, IEC/GB in China, REACH and RoHS in Europe). And increasingly, regulations are restricting traditional halogenated flame retardant additives due to environmental and health concerns.

In this guide, we will break down:

• UL94 – the most widely used flammability standard for plastics.
• Regional regulations – REACH, RoHS, China GB, and aerospace FAR 25.853.
• Non‑halogen flame retardant solutions – including inherently FR polymers like PEI and advanced PP compounds.
• Future trends – PFAS bans and stricter e‑waste rules.

We will also show how CISKO NEW MATERIAL helps you stay compliant with up‑to‑date documentation and materials that meet or exceed current and upcoming regulations.

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2. Understanding UL94 – The Global Benchmark

UL94 is a standard published by Underwriters Laboratories that classifies the flammability of plastic materials based on their response to a small flame under controlled conditions. It is widely adopted in North America, and many international buyers require UL94 compliance.

2.1 Testing Method Overview

UL94 tests are conducted on a set of five specimens. The test involves applying a 20 mm (about 0.8 inch) high flame for specific durations and observing:

• Whether the specimen ignites.
• How long it continues to burn after the flame is removed.
• Whether flaming drips ignite cotton placed below.

Two orientations are used:

• Vertical burn – for V‑0, V‑1, V‑2, and 5VA/5VB ratings.
• Horizontal burn – for HB rating.

2.2 Ratings Explained (from least to most flame resistant)

Rating	Description	Typical Application
HB (Horizontal Burn)	Slow burning (≤ 75 mm/min) on horizontal specimen.	Low‑risk parts like enclosures not near ignition sources.
V‑2	Vertical – self‑extinguishes within 30 seconds, allows flaming drips that ignite cotton.	Some E&E parts where drips are contained.
V‑1	Vertical – self‑extinguishes within 30 seconds, no flaming drips allowed.	Improved safety over V‑2.
V‑0	Vertical – self‑extinguishes within 10 seconds, no flaming drips.	High‑safety components: connectors, housings, switches.
5VA	Vertical – tested with a higher flame (500W) for five applications of 5 seconds each; no burn‑through (hole) allowed.	Very thin walls (as low as 1.2–3 mm) in demanding applications.
5VB	Similar to 5VA but allows burn‑through (hole).	Less stringent than 5VA.

2.3 Minimum Thickness for Each Rating (Examples)

Flame retardancy is thickness‑dependent. A material may achieve V‑0 at 1.5 mm but only V‑2 at 0.8 mm. Always check the UL Yellow Card for the exact thickness rating.

Examples from our portfolio:

• Ultem 2300 (30% glass PEI) – V‑0 at 0.25 mm, 5VA at 1.2 mm (exceptionally thin).
• Ultem 1000 (unfilled PEI) – V‑0 at 0.75 mm, 5VA at 3.0 mm.
• Hanwha Total FH44 (flame retardant PP) – V‑0 at 1.5 mm (non‑dioxin formulation).
• Hanwha Total FB51 (flame retardant PP) – V‑2 at 1.5 mm (high impact).

2.4 The UL Yellow Card – What More It Tells You

When a plastic is UL‑recognized, the manufacturer obtains a UL Yellow Card (online at UL Product iQ). Beyond the V‑0/5VA rating, the Yellow Card provides:

Parameter	Meaning	Why Important
HWI (Hot Wire Ignition)	Resistance to ignition from a glowing wire.	For live electrical parts.
HAI (High Amp Arc Ignition)	Resistance to ignition from an electrical arc.	For high‑voltage components.
CTI (Comparative Tracking Index)	Resistance to tracking (surface conduction) under wet, contaminated conditions.	For insulators in humid environments.
RTI (Relative Thermal Index)	Maximum continuous use temperature for 100,000 hours.	For thermal aging performance.

CISKO can provide UL Yellow Cards for all SABIC Ultem and Hanwha Total PP grades upon request.

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3. Regional Regulations – A Global Patchwork

Beyond UL94, other regulations apply depending on where your product is sold or used.

3.1 European Union: REACH, RoHS, and WEEE

• REACH (EC 1907/2006) – Registration, Evaluation, Authorisation and Restriction of Chemicals. It restricts substances of very high concern (SVHC), including many flame retardants (e.g., deca‑BDE, HBCD). Suppliers must declare if any SVHC >0.1% w/w.
• RoHS (2011/65/EU) – Restriction of Hazardous Substances in electrical and electronic equipment. Limits lead, mercury, cadmium, hexavalent chromium, PBB, PBDE. Halogenated flame retardants are not automatically banned, but some are restricted.
• WEEE – Waste Electrical and Electronic Equipment. Encourages design for recyclability; certain FR additives can make recycling difficult.

Impact on material selection: Many traditional brominated flame retardants are being phased out. Non‑halogen solutions are preferred.

3.2 China: GB Standards and China RoHS

• GB/T 2408 – China’s equivalent of UL94 (vertical/horizontal burning test).
• GB 4943.1 – Safety of audio/video and IT equipment (similar to IEC 62368).
• China RoHS – Requires disclosure of hazardous substances; similar to EU RoHS but with different marking requirements.

Our materials (SABIC Ultem, Valiant PEI, Hanwha Total PP) are fully compliant with China RoHS and relevant GB standards.

3.3 United States: UL94, FAR 25.853, and NFPA

• UL94 – as described above, widely required for E&E products.
• FAR 25.853 – Federal Aviation Regulation for aircraft interior materials. Requires heat release (OSU test) and smoke density (NBS smoke chamber). PEI (Ultem) is fully compliant; many PP grades are not suitable for aerospace.
• NFPA 130 – Fire safety for rail transit vehicles; also specifies heat release and smoke limits.

3.4 Global Trend: Moving Away from Halogenated FR Additives

Why? Halogenated flame retardants (especially brominated and chlorinated) can:

• Produce toxic and corrosive fumes (e.g., HBr, dioxins) when burned.
• Persist in the environment and bioaccumulate.
• Face increasing regulatory restrictions (e.g., EU’s POPs regulation, US EPA’s TSCA).

As a result, many OEMs (e.g., Apple, Dell, HP) have issued non‑halogenated (halogen‑free) specifications, typically requiring <900 ppm Cl + Br combined.

Solution: Use inherently flame retardant polymers (PEI, PSU, PPSU) or non‑halogen additive systems (phosphorus‑based, nitrogen‑based, or inorganic).

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4. Non‑Halogen Flame Retardant Solutions

4.1 Inherently Flame Retardant Polymers – No Additives Needed

Some high‑performance polymers achieve UL94 V‑0 without any flame retardant additives because of their aromatic chemical structure. These are the most “future‑proof” materials.

Polymer	Typical V‑0 thickness	Advantages
PEI (Ultem, Valiant)	0.25–0.75 mm	Also low smoke, high Tg (217°C), excellent mechanicals.
PSU (Polysulfone)	1.5–3.0 mm	Lower cost than PEI, but lower temp (Tg 185°C).
PPSU (Polyphenylsulfone)	1.5–3.0 mm	Higher impact, autoclave resistant.
PEEK (needs additives)	Usually V‑0 with fillers	Expensive, not inherently FR.

CISKO’s focus: We supply PEI from SABIC (Ultem) and Valiant – both inherently FR without halogens.

4.2 Non‑Dioxin Flame Retardant PP (Hanwha FH44)

For polypropylene, which is inherently flammable, flame retardant additives are required. However, traditional brominated FRs can produce dioxins under certain combustion conditions. Hanwha TotalEnergies FH44 is a non‑dioxin V‑0 PP compound.

• Rating: UL94 V‑0 at 1.5 mm.
• Application: Washing machine motor cases, air conditioner heater housings, automotive E&E parts.
• Safety: No dioxins produced, safe for indoor appliances.
• Thermal stability: Long‑term RTI >120°C, good heat deformation resistance (HDT 134°C).

Another grade, FB51, is a V‑2 rated high‑impact flame retardant PP for less demanding applications.

4.3 Comparing FR Additive Types

Type	Examples	Pros	Cons
Halogenated (brominated)	Deca‑BDE, DBDPE	High efficiency, low cost	Toxic combustion products, regulatory pressure
Halogen‑free (phosphorus)	RDP, BDP, phosphinates	Lower toxicity, good char formation	Can be more expensive, may affect processing
Halogen‑free (nitrogen)	Melamine derivatives	Low smoke	Less effective for V‑0 alone
Inorganic (metal hydroxides)	ATH, MDH	Very safe, low cost	Requires high loadings (degrades mechanicals)

For PEI, no additive is needed. For PP, Hanwha uses advanced non‑dioxin systems that meet current and near‑future regulations.

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5. How CISKO Supports Compliance

At CISKO NEW MATERIAL, we understand that compliance is not just about the material – it’s about documentation and traceability.

5.1 Full REACH, RoHS, and UL Documentation

For every product we supply, we provide:

• REACH SVHC declaration (updated as new substances are added).
• RoHS compliance certificate (including lead, mercury, cadmium, etc.).
• UL Yellow Card (for SABIC Ultem and Hanwha Total PP – upon request).
• TDS, SDS, COA/COC for batch traceability.

5.2 PEI – All Grades REACH/RoHS Compliant

Whether you choose SABIC Ultem or Valiant PEI, all our PEI materials are:

• REACH registered (no SVHC >0.1%).
• RoHS exempt or fully compliant (no restricted substances).
• Halogen‑free for natural/uncolored grades (IEC 61249‑2‑21 compliant).

5.3 PP – Hanwha Total Grades

• FH44 (V‑0) – Non‑dioxin formulation, REACH/RoHS compliant, no SVHC.
• FB51 (V‑2) – Standard FR PP, fully compliant with current regulations but may be less suitable for future non‑halogen preferences.
• TB and GH series – Not flame retardant (used for structural, not FR applications).

5.4 Additional Certifications Available

We can also provide (on request for qualified customers):

• FDA compliance (for Ultem 1285 and select grades).
• FAR 25.853 (for aerospace PEI).
• ISO 10993 biocompatibility (for certain medical grades – check availability).

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6. Future Outlook: PFAS Bans and Stricter E‑waste Rules

6.1 PFAS (Per‑ and Polyfluoroalkyl Substances) – A Growing Concern

PFAS are a large class of chemicals used in many industrial applications, including some flame retardant formulations (e.g., fluorinated surfactants in FR coatings). The EU is considering a broad PFAS ban (the “universal PFAS restriction proposal”), and several US states have already restricted PFAS.

Impact on plastics: Some FR additives containing PFAS could be banned. However, inherently FR polymers like PEI contain no PFAS and are therefore future‑proof. For PP, Hanwha’s FH44 uses a non‑fluorinated, non‑halogen system.

CISKO’s position: We proactively select materials that do not contain PFAS or halogenated FRs above trace levels.

6.2 Stricter E‑waste Regulations

As electronic devices proliferate, e‑waste recycling is becoming more regulated. The EU’s Circular Economy Action Plan and China’s Extended Producer Responsibility rules encourage design for recycling. Plastics that contain high levels of halogenated FRs are harder to recycle and may face disposal bans.

Trend: More OEMs will require V‑0 plastics that are halogen‑free (e.g., PEI) to simplify recycling.

6.3 Performance Requirements Are Also Increasing

UL94 V‑0 is no longer sufficient for some demanding applications. For thin‑wall electronics (e.g., laptops, smartphones), 5VA or VTM‑0 (thin film) ratings are becoming standard. PEI’s ability to achieve V‑0 at 0.25 mm and 5VA at 1.2 mm gives it a strong advantage over many other polymers.

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7. Conclusion – Ensure Your Supply Chain is Compliant

Flame retardant regulations are complex, regional, and evolving. But you do not need to navigate them alone. Choosing the right material upfront – and working with a supplier that provides full documentation – saves time, reduces risk, and keeps your products on the market.

Key takeaways:

• UL94 – Understand the difference between HB, V‑2, V‑1, V‑0, and 5VA. Check the thickness rating on the UL Yellow Card.
• Regional rules – REACH and RoHS in EU, China RoHS/GB, and FAR 25.853 for aerospace.
• Non‑halogen FR – Inherently FR polymers (PEI) are the safest long‑term choice; for PP, use non‑dioxin formulations like Hanwha FH44.
• Future trends – PFAS bans and stricter e‑waste rules will favor materials that contain no halogenated or PFAS‑based FR additives.

CISKO NEW MATERIAL supplies fully compliant engineering plastics with up‑to‑date documentation. Whether you need PEI (Ultem or Valiant) or flame retardant PP (Hanwha FH44, FB51), we can provide the compliance package you require.

📧 Contact us for the latest certification packages: info@pp-pei.com
📞 Call: +86 13538114678
🔗 Explore our flame retardant products:

• Ultem PEI 1010 (V‑0 at 0.75 mm)

Request a compliance dossier for your target market today.