he data center industry is in the throes of an AI-fueled transformation, with data center capacity projected to grow from 60 gigawatts (GW) today to as much as 298 GW by 2030, with about 70% of that dedicated to AI. That means we can expect a massive influx of new data centers, most of which will feature new approaches to design and infrastructure to support AI workloads. As a result, the industry is expected to make nearly US$7 trillion worth of capital expenditures over that time, with $5.2 trillion of that investment dedicated to AI.

A growing chunk of that investment is going to thermoplastics, which are becoming increasingly common in chip and facility design as AI changes the power and thermal profiles of the data center. Thermoplastics such as polycarbonate, PVC and CPVC are replacing perforated metal and other materials because they perform as well or better than legacy materials and have other advantages. More specifically, materials like multiwall PC, monolithic PC, acrylic, HDPE and PP are also designed for places where metal can’t be used and corrosion or flame resistance is needed. Applications where these thermoplastics are best suited include:

• Airflow and containment systems
• Door and panel glazing
• Rack doors and side panels
• Plenum partitions and ceiling tiles
• Cable management and power distribution

Specifically, the benefits of thermoplastics are:

• Durable and impact-resistant
• Lightweight
• Flame-resistant (meeting UL, FM and other flammability ratings)
• Chemical-resistant (depending on the material and the chemicals)
• Corrosion-resistant
• Highly available
• Cost-effective

Some high-performance thermoplastics are also used in semiconductors. They hold up well in extreme environments, including the high temperatures produced in servers, and provide excellent dielectric properties to prevent electrical interference and short circuits. They are also a good fit for chip manufacturing equipment because they stand up well to hydrochloric and nitric acids, as well as other strong acids used at various stages of the manufacturing process.

Stepping back from the chip, thermoplastics play an increasingly prominent role that will only grow in the AI-focused data centers of the future. The same general properties that make thermoplastics appealing in countless other applications are suddenly in demand in data centers that get hotter with every ChatGPT query and where every square foot is at a premium.

Most of these aisle containment systems use thermoplastics — most commonly polycarbonate — to enclose the area between two aisles of racks in such a way that either the cold air or the hot air is captured and reused appropriately. Polycarbonate is a popular choice because it provides the durability, transparency and heat resistance needed for the job. When compared to pre-existing substrates, it’s relatively inexpensive and lightweight, an important factor in the raised floor environments common to air-cooled data centers.

Aisle containment systems keep hot and cold air segregated, enhancing server performance and cooling efficiency.

Those raised floor tiles are another common application for thermoplastics — again, with multiwall polycarbonate being the usual choice. Data centers have used raised floors with perforated tiles that allow cold air to reach the rack for decades. Traditionally, those tiles have been made of cement-filled steel, hollow steel or wood core encased in a metal shell. For a variety of reasons, especially material costs, data center designers are turning to thermoplastics for the same performance characteristics at a lower cost.

In both applications, raised floors and ceilings, polycarbonate can provide an added benefit metal can’t match: transparency. Clear polycarbonate in floor and ceiling tiles allows data center managers to see cables, duct work, plumbing and conduit, and physically inspect conditions without removing the tiles.

Some rack manufacturers are beginning to use multiwall polycarbonate on the front and rear doors of their racks to reduce the overall weight of the rack without compromising heat resistance or ease of fabrication. Just like the floor and ceiling tiles, clear polycarbonate doors can make it easier to see what’s inside compared to the more common perforated steel. Some rack doors are made with tempered glass inserts, but that adds weight. Polycarbonate delivers all the benefits of glass at a lower weight and price.

Clear polycarbonate raised floor tiles allow data center managers an easy view of the systems running under the floor throughout the facility.

• McKinsey & Company. (2024). AI power: Expanding data center capacity to meet growing demand. https://www.mckinsey.com/industries/technology-media-and-telecommunications/our-insights/ai-power-expanding-data-center-capacity-to-meet-growing-demand