ASTM D1938 Plastic Film and Thin Sheeting Trouser-Tear Test

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Tear & Shear Test evaluates material resistance to tearing and shearing forces, measuring critical strength parameters for quality control. Tear tests (Elmendorf/trouser/trapezoidal) assess resistance to crack propagation in films/fabrics, while shear tests measure resistance to parallel forces in joints/bolts. UnitedTest provides universal testing machines (10KN-600KN) with specialized fixtures for both tests, compliant with ASTM D624/D3164 and ISO standards, serving automotive, packaging and construction industries.

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ASTM D1938 Trouser Tear‑Propagation Resistance Tester for Plastic Film | UnitedTest

ASTM D1938 evaluates tear‑propagation resistance of plastic film and thin sheeting up to 1 mm thickness using trouser single‑tear method with CRE tensile testing. UnitedTest produces ASTM D1938 compliant test machines to measure steady crack propagation force for flexible packaging QC and polymer material evaluation.

ASTM D1938 is the widely‑accepted North American standard test method for measuring tear‑propagation resistance via the trouser single‑tear method on plastic film and thin sheeting. This standard focuses on steady crack propagation across pre‑slit specimens with maximum thickness of 1 mm, performed on constant‑rate‑of‑grip‑separation tensile testing apparatus. Unlike crack‑initiation tear tests, ASTM D1938 specifically characterizes the force needed to keep an existing crack travelling through the material, instead of measuring the force to start a brand‑new fracture.

This tear‑propagation test delivers critical performance data for flexible packaging materials, polymer films, and thin plastic sheets, supporting material R&D, incoming material inspection, batch‑to‑batch quality control, and product certification for packaging converters, plastic film manufacturers and third‑party testing laboratories.

UnitedTest engineers and manufactures fully ASTM D1938 compliant trouser tear‑propagation resistance testing machines. Our CRE‑based tensile test equipment delivers stable, repeatable force readings for pre‑slit plastic film and thin sheeting specimens, ideal for lab research, factory quality assurance and material compliance verification.

Test Principle

A "trouser-shaped" specimen – a rectangular strip with a longitudinal slit that creates two legs – is clamped in a constant-rate-of-grip-separation tensile machine. The two legs are pulled apart at a constant speed, and the force needed to keep the pre-cut tear propagating through the un-slitted portion is recorded as a function of time (or extension).

The resulting load–time curve reveals the material's tear behavior:

Slightly or non-extensible materials produce a relatively flat plateau → the average tear-propagation force is reported .

Highly extensible materials show a pronounced peak → the initial force, maximum force, and extension at maximum force are reported instead, because the leg-deformation energy greatly exceeds the actual tearing energy .

In short, ASTM D1938 measures tear-propagation resistance, i.e., how difficult it is for an existing slit or nick to keep growing—a property that is distinct from tensile strength or tear-initiation resistance.

Specific Test Method

ASTM D1938 employs a constant-rate-of-grip-separation (CRE) single-tear method:

A trouser-shaped specimen is prepared with a central longitudinal slit.

The two legs ("Tongue A" and "Tongue B") are secured in the upper and lower grips of a tensile tester.

The grips separate at a constant speed of 250 mm/min ±5 %.

The tear propagates through the un-slitted 25 mm (1 in.) section.

Load vs. extension is recorded autographically.

The average tear force (or initial/maximum force for extensible films) is calculated from the plateau region, disregarding the initial and final transients .

This is fundamentally different from pendulum-based methods such as ASTM D1922 (Elmendorf), which measure the energy lost by a swinging pendulum.

Test Specimen Info:

Dimensions: Specimen overall size: 75 mm total length × 25 mm width. Central slit length = 50mm. Dimensional tolerance: within 0.5 % of nominal dimensions.

Thickness uniformity: Thickness variation across un‑slit zone ≤ 5 %.

Cutting requirement: Edges and slit tip must be clean and free from nicks or jagged cuts.

Anisotropy requirement: Prepare minimum 5 valid specimens for machine direction (MD) and 5 for transverse direction (TD) separately, as extruded films show directional tear differences.

Invalid behaviour: If tear drifts sideways and reaches specimen edge, record this deviation in the final test report (specimen is not automatically discarded, unlike ISO 6383‑1).

ASTM D1938 Plastic Film and Thin Sheeting Trouser-Tear Test

ASTM D1938 Plastic Film and Thin Sheeting Trouser-Tear Test Equipment

CRE tensile testing machine	- One fixed grip assembly and one movable cross‑head‑driven grip assembly. - Mandatory test speed: 250 mm/min ± 5 % grip separation rate. - Load measuring system: ±1 % force accuracy; machine inertia shall be negligible at test speed. Calibration follows ASTM E4. - Data recording: continuous load‑vs‑extension / load‑vs‑time output for curve analysis.
Tear test Fixtures	Permits self‑aligning grips (preferred) or rigid fixed grips; rubber‑lined jaws are recommended to prevent specimen slippage.
Thickness measuring device	Complies with ASTM D5947 / D6988; resolution ≤ 0.0025 mm. Controlled measuring pressure prevents specimen deformation (70 kPa for ultra‑thin films ≤0.025 mm; 160‑185 kPa for stiffer sheets).
Sharp cutting die	Specimen die with 5° negative rake cutting edge for clean, nick‑free specimen edges. Cutting surface must be soft enough to protect die blades.

Test Procedure Of ASTM D1938 Plastic Film and Thin Sheeting Trouser-Tear Test

1. Cut specimens using qualified sharp die; check edge and slit‑tip quality. Measure specimen thickness at multiple positions below the slit.

2. Condition specimens for ≥ 40 h under 23 °C / 50 % RH following ASTM D618.

3. Set tensile tester initial grip separation = 50 mm. Mount one trouser leg into fixed grip and the second leg into movable grip. Align specimen central axis with the pull centre‑line to avoid skewed loading.

4. Set cross‑head speed to 250 mm/min, start test, record full load‑extension / load‑time trace.

5. Run test until tear fully propagates through the un‑slit 25 mm section of specimen. Record if tear deviates sideways to sample edge.

6. Repeat for minimum five replicates in MD and TD directions respectively.

7. Process recorded curves:

- For low‑extensible films: compute average tear‑propagation force over valid 25.4 mm tear interval.

- For highly‑extensible films: extract initial tear‑propagation force, maximum force and corresponding extension.

8. Compute arithmetic mean values and standard deviation.

9. Compile full test report as per standard. Mandatory report items include material identification, specimen thickness, replicate count, test date, mean force values for each test direction, standard deviation, and notes on any off‑centre tearing events.

Test Parameters & Stipulations:

Specimen thickness	≤ 1 mm (film defined as ≤ 0.25 mm)
Grip separation speed	250 mm/min ±5 %
Initial grip separation	50 mm (2 in.)
Un-slitted tear length	25 mm (1 in.)
Number of specimens	≥ 5 in MD and ≥ 5 in TD
Data evaluation window	Average load over a 25.4 mm (1 in.) interval, disregarding initial/final transients

Industrial Application Fields

ASTM D1938 is employed wherever thin plastic films and sheeting must resist tear propagation:

Flexible packaging – food pouches, shrink wraps, laminated films, stand-up bags.

Retail & consumer bags – T-shirt sacks, garbage bags, shrink bundles.

Agricultural films – mulch films, greenhouse covers, silage wraps.

Medical & pharmaceutical – sterile barrier packaging, surgical drapes, IV bags.

Industrial liners – geomembranes, protective covers, battery separator films.

Specialty films – adhesive tapes, label stocks, photovoltaic backsheets.

In all these sectors, D1938 serves as a quality-control gate and a material-ranking tool that supports product development and regulatory compliance.

Related standard:

ISO 6383-1	Plastics. Film and sheeting. Determination of tear resistance-Trouser tear method
ASTM D1922	Propagation Tear Resistance by Pendulum (Elmendorf) Method .
JIS K 7128-1	Plastics -- Film and sheeting -- Determination of tear resistance -- Part 1: Trouser tear method
GB/T 16578.1	Plastics - Film and sheeting - Determination of tear resistance - Part 1：Trouser tear method
BS 2782-3 METHOD 360B	Methods of testing plastics. Mechanical properties. Determination of tear resistance of plastics film and sheeting by the trouser tear method
NF T54-140-1	Plastics - Film and sheeting - Determination of tear resistance - Part 1 : trouser tear method.
ASTM D1938	Standard Test Method for Tear-Propagation Resistance (Trouser Tear) of Plastic Film and Thin Sheeting by a Single-Tear Method
DIN 53363	Testing of plastic films - Tear test using trapezoidal test specimen with incision
ISO 8067	Flexible cellular polymeric materials: Determination of tear strength
ASTM D1004	Standard Test Method for Tear Resistance (Graves Tear) of Plastic Film and Sheeting
ISO 11897	Packaging - Sacks made from thermoplastic flexible film - Tear propagation on edge folds

Keywords: ASTM D1938 trouser tear‑propagation resistance test, ASTM D1938 single‑tear method tester, plastic film tear propagation force testing machine, thin sheeting trouser tear test equipment, ≤1mm plastic film tear‑propagation analyzer, constant‑rate‑of‑grip‑separation tear tester, pre‑slit specimen tear resistance rig, flexible packaging polymer film tear performance tester, plastic film crack propagation measurement device, UnitedTest ASTM D1938 compliant material testing machine, thin plastic sheet fracture propagation laboratory instrument, packaging film quality control tear tester

WDW Series Computer Control Electronic Universal Testing Machine made by UNITEDTEST range from 100N to 600KN load capacity with various models like single columns, table type, door frame type etc., is used to perform tension, compression, flexure/bending, shearing, peeling etc., test for metal and nonmetal specimens.

Tear fixture ISO 505, ASTM D1004, vise grip or self-tightening roller grips are the most popular for this application and the least expensive. They can be provided with a rubber faced surface to measure the tear resistance strength of flexible plastic film and sheeting.

T-Peel Resistance Test Fixture for Adhesives is based on ASTM D1876 standard, used to measure the adhesion strength of adhesive maeterial. ASTM D1876 peel strength test method is commonly used to measure the strength of adhesive bonds between two sealed materials.

Q1. What is ASTM D1938?

A: ASTM D1938‑19 is the current ASTM International standard entitled "Standard Test Method for Tear‑Propagation Resistance (Trouser Tear) of Plastic Film and Thin Sheeting by a Single‑Tear Method." It specifies how to measure the force required to propagate an existing tear in plastic film or thin sheeting whose thickness is 1 mm (0.04 in.) or less . (Film is arbitrarily defined as sheeting ≤ 0.25 mm thick.) The method is not applicable to materials that fail brittly during testing .

Q2. Why is ASTM D1938 important?

A: Tear‑propagation resistance is a critical material property for any plastic film or thin sheet that must survive nicks, slits, or accidental cuts during manufacturing, filling, transportation, or end‑use. ASTM D1938 matters because :

It measures propagation, not initiation – The test tells you how hard it is for an existing tear to keep growing, which closely mirrors real‑world failure modes in packaging and flexible materials.

Enables material ranking – It provides data for ranking the tear‑propagation resistance of plastic films and sheeting of similar composition .

Supports commercial specifications – The method is used for specification acceptance testing, engineering design, quality assurance, and material‑to‑material comparison .

Distinguishes extensibility behavior – The load‑time curve differentiates slightly/non‑extensible films (average plateau force) from highly extensible films (initial + peak force), preventing misinterpretation of leg‑deformation energy as tearing energy .

Global relevance – While ASTM D1938 is the U.S. reference, it is technically similar to ISO 6383‑1 (though not equivalent – different specimen size and test speeds) , making it essential for manufacturers serving North American markets.

⚠️ The standard explicitly notes that data from specimens of dissimilar thickness are usually not comparable , and actual use performance may not perfectly correlate with lab data. The method should be used for specification acceptance only after reproducibility for the specific material is demonstrated .

Q3: What are the main differences between ASTM D1938‑19 and ISO 6383‑1 trouser‑tear standard?

A: Although they share the trouser‑tear test principle, they are **not technically equivalent** and test results cannot be converted directly

Item	ASTM D1938‑19	ISO 6383‑1:2015
Specimen size	75 mm × 25 mm; slit length 50 mm	150 mm × 50 mm; slit length 75 mm
Test speed	Fixed 250 mm/min ± 5 %	200 mm/min ±10 % or 250 mm/min ±10 %
Off‑centre tear handling	Record deviation in report, specimen is NOT discarded	Must discard specimen and retest
Grip type	Self‑aligning grips are permitted / preferred	Swivel / self‑aligning grips are forbidden
Evaluated tear segment	25.4 mm stable tear interval	Middle 50 mm tear segment (exclude first 20 mm and last 5 mm)

Q4: What is the mandatory test speed and initial grip separation for ASTM D1938‑19?

A: Fixed cross‑head / grip‑separation speed: 250 mm/min ± 5 %. Initial grip separation before test start shall be 50 mm. No alternative test speed is allowed in the standard protocol.

Q5: How do I process load‑time curves for low‑extensible vs highly extensible films?

A: 1. Low‑/slightly‑extensible films (stable plateau curve): Take average tear‑propagation force over a stable 25.4 mm tear interval, ignore initial and final parts of curve.

2. Highly‑extensible stretchy films (no flat plateau): You cannot use average plateau force. You must report three sets of data: initial tear‑propagation load, maximum tear force, extension at maximum force for each specimen set.

Q6: My test results show high variability. What are common root causes?

A:1. Poor specimen cutting: tiny nicks or jagged edges at slit tip or specimen borders.

2. Specimen slippage inside grips; mis‑aligned specimen axis against pull direction.

3. Insufficient conditioning time or wrong temperature‑humidity settings.

4. Thickness inconsistency of test specimens.

5. For highly‑extensible films, incorrect curve data selection (taking peak force instead of valid stable tear section).

Q7. Why choose UnitedTest for ASTM D1938 testing?

A: Precision ASTM D1938 Trouser Tear Testers for Plastic Film & Thin Sheeting

UnitedTest is a professional manufacturer of material testing instruments. Our **ASTM D1938‑19 trouser tear test system** fully complies with American standard ASTM D1938‑19 for tear‑propagation‑resistance measurement of plastic film and thin sheeting (max thickness 1 mm). Widely deployed by North‑America‑oriented polymer factories, flexible‑packaging producers, agricultural‑film manufacturers, QC laboratories, R&D centres and independent third‑party inspection institutes globally.

The ASTM D1938 trouser‑tear method evaluates the force required for an existing crack to propagate across pre‑slit specimens, simulating real‑world damage from scratches and nicks. Different from pendulum‑type Elmendorf testers (ASTM D1922), this test runs at constant 250 mm/min grip separation speed and outputs continuous load‑vs‑extension curves, supporting differentiated data processing for low‑extensible and highly‑stretchable plastic films.

UnitedTest ASTM D1938 Tester – Key Features

Constant‑rate‑of‑crosshead‑movement (CRE) tensile frame – e.g., the DSTM Series 5‑25 kN table‑top universal testing machines – with twin ball‑screw drive, closed‑loop servo control, and speed accuracy of ±0.1 % for precise 250 mm/min operation .

High‑resolution load cell with ±1 % accuracy per ASTM E4, capable of resolving the low forces typical of thin‑film tear testing .

Self‑aligning grips (rubber‑faced, pneumatic or mechanical) that secure trouser‑leg specimens without slip or uneven stress distribution, as required by ASTM D1938 .

Precision die cutter with 5° negative‑rake blade for preparing trouser‑shaped specimens to Fig. 3 dimensions with ±0.5 % tolerance .

Integrated thickness‑measurement module compliant with ASTM D5947 / D6988, with selectable contact pressures for thin vs. thick films .

Software with pre‑configured ASTM D1938 method, real‑time load‑vs‑extension plotting, automatic identification of the stable tear‑propagation region, and calculation of average, initial, and peak tear‑propagation forces .

Conditioning chamber compatibility – maintains ASTM D618 atmosphere (23 °C / 50 % RH) for the mandatory ≥40 h preconditioning .

Multi‑standard compliance – one UnitedTest machine performs ASTM D1938, ASTM D882, ASTM D1004, ASTM D1922, ASTM D2582, ASTM D2261, ISO 6383‑1, and many more, reducing laboratory capital expense.

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