Loading page
Should I use ABS or polycarbonate?
Use ABS for general housings, covers and consumer parts: it costs about 20% less, molds easily, and paints and plates well. Use polycarbonate when parts must survive drops, run hotter, or be clear: PC is roughly 2–4× tougher in notched impact, has about 60 °F (35 °C) higher heat deflection, and transmits 88–90% of light in clear grades.
ABS
Polycarbonate (PC)
By the numbers
Priced on the same representative part: housing, injection molding, 10,000 pcs.
Tensile strengthMPa
ABS
43
PC
65
Densityg/cm³
ABS
1.05
PC
1.2
Max service temp°C
ABS
80
PC
115
Elongation%
ABS
25
PC
110
Raw material cost$/kg
ABS
3
PC
3.8
Which should you pick?
Pick ABS when
- Cosmetic housings will be painted, plated or textured
- Service is indoor and near room temperature
- Resin cost matters
- The part is chrome-plated trim, a knob or a handle
Pick PC when
- Drop, impact or cold-temperature toughness is required
- The part is a clear lens, window or light cover
- Continuous service runs near 240 °F (115 °C)
- It is a machine guard or safety shield
Key differences
| ABS | PC | |
|---|---|---|
| Clarity | Opaque | Clear grades transmit about 88–90% |
| Heat deflection at 264 psi | About 185–205 °F (85–95 °C) | About 270 °F (130 °C) |
| Molding | Forgiving; low, uniform shrink of 0.4–0.7% | Must be dried to 0.02% moisture or less; runs hotter |
| Plating and paint | Most common plated plastic; paints easily | Paints well; rarely plated |
| Chemical weak spots | Acetone and many solvents | Stress-cracks with some solvents, oils and cleaners |
| Outdoor use | Yellows and embrittles; use ASA or paint | Yellows; use UV-stabilized grades or a hard coat |
Questions
Is polycarbonate stronger than ABS?
Yes. PC runs about 9,400 psi (65 MPa) tensile versus 6,200 psi (43 MPa) for ABS, with roughly 2–4× the notched impact strength. It also stretches much further before breaking, which is why guards and lenses use it.
Is ABS or polycarbonate better outdoors?
Neither is good unprotected; both yellow and lose impact strength in sunlight. For opaque outdoor parts, ASA molds like ABS and weathers well. For clear outdoor parts, use UV-stabilized or hard-coated PC, or acrylic if impact loads are low.
What about a PC/ABS blend?
PC/ABS splits the difference: better impact and heat resistance than ABS, easier flow and better surface than PC, at about 30–40% more than ABS. It is the standard for laptop, charger and automotive interior housings.
Try both on your part.
The builder prices the same geometry in every suitable process and material, with DFM for each.