ABS vs Polycarbonate: Which is Better for Your Application

Added by Sam Brown
Head of Sales & Marketing at Penta Precision

Choosing the right material for your project is critical. ABS and polycarbonate are both popular thermoplastics, but they offer very different properties and advantages. This guide will help you compare them clearly so you can make the best decision based on your application needs.

ABS vs Polycarbonate: Quick Comparison

Factor ABS Polycarbonate
Strength and Impact Good impact resistance, rigid but less durable under stress Extremely high impact resistance, tough and flexible
Heat Resistance Stable up to ~97°C, deforms under prolonged heat Withstands up to ~132°C, retains strength when heated
Optical Properties Opaque, good surface finish, easy to colour/texture Naturally transparent, high optical clarity, can be coated for scratch resistance
Cost and Processing Lower material and processing costs, easy to mold/print 30–50% more expensive, requires higher processing temperatures and tooling
Environmental Resistance Poor UV resistance unless stabilized, less durable outdoors Better UV and weather resistance, ideal for harsh environments
Recyclability Easier to recycle, but petrochemical origin limits sustainability Harder to recycle, but long service life offsets environmental load
Best For Budget-friendly projects, prototypes, casings, automotive interiors High-performance, transparent, heat-resistant parts (lenses, medical devices, enclosures)

Why Compare ABS and Polycarbonate

Both ABS and polycarbonate are widely used in high-precision industries. They’re common in electronics, automotive, medical devices, and consumer products. Understanding their key differences will help you avoid costly mistakes.

ABS offers strength, impact resistance, and affordability. Polycarbonate delivers better clarity, toughness, and higher heat resistance. Knowing where each excels will help you choose the best material for machining, prototyping, or production.

Key Differences: ABS vs. Polycarbonate

When comparing ABS plastic vs polycarbonate, there are several important factors to evaluate. Below we break down each key property, so you can match the right plastic to your requirements. 

Material & Mechanical Properties

ABS is a blend of acrylonitrile, butadiene, and styrene. This structure gives it good toughness, rigidity, and scratch resistance. It is an ideal choice for cost-sensitive applications that still require mechanical reliability.

Polycarbonate is made from bisphenol A (BPA) and phosgene or alternatives. It offers superior impact resistance, transparency, and strength. PC is also more flexible and less brittle than many other plastics, making it ideal where durability under force is needed.

A blended version, PC-ABS, combines the best of both: ABS’s ease of processing and polycarbonate’s high performance. If you're evaluating abs vs pc material properties, this hybrid might also be worth considering. It’s especially useful in parts needing both toughness and surface quality. For early-stage development using either material, prototype machining for engineering plastics can help you test form, fit, and function effectively.

Heat Resistance & Thermal Performance

ABS performs well up to about 97°C. It is stable at room temperature and holds its shape under typical operational use. However, prolonged exposure to high heat can lead to deformation.

Polycarbonate has a much higher heat deflection temperature, around 132°C. This makes it suitable for components exposed to higher temperatures or thermal cycling. It also retains its mechanical properties better when heated.

If your parts will undergo machining or operate near heat sources, PC is the safer bet. This becomes important when considering the heat resistance impact on tooling or evaluating part stability post-machining.

Optical & Surface Characteristics

Polycarbonate is transparent due to its non-crystalline polymer structure. This makes it suitable for lenses, visors, and any part requiring optical clarity. It can also be coated to enhance scratch resistance.

ABS is typically opaque with a matte or semi-gloss finish. It’s often used in products where appearance matters, like casings and housings. The surface can be dyed, textured, or finished to suit different applications.

If you need optical clarity, PC is unmatched. For aesthetic finishes and design flexibility, ABS remains a top choice.

Cost & Processing

Cost is a deciding factor in many projects. ABS is more affordable, with typical costs ranging from £10–20/kg. It’s easy to process using standard injection moulding or FDM 3D printing setups.

Polycarbonate is around 30–50% more expensive, often costing £25–30/kg. It requires higher processing temperatures, which means more specialised equipment is needed. This adds to the overall manufacturing cost.

ABS is the better option for high-volume, budget-conscious projects. If performance matters more than cost, PC offers strong long-term value.

Environmental Resistance & Safety

Both materials are recyclable, but in different ways. ABS is easier to recycle, though its petrochemical origins pose environmental concerns. Polycarbonate is harder to recycle but offers better performance under harsh conditions.

ABS has low UV resistance unless stabilised. Without additives, it can degrade in outdoor settings, becoming brittle or discoloured. Polycarbonate performs better in outdoor use but still benefits from coatings for long-term UV exposure.

For environmentally sensitive applications, assess full lifecycle impact. If you need UV protection, look for stabilised or coated versions of either material.

Which Material is Better and When?

Choosing between ABS material vs polycarbonate depends on your project’s priorities. Each material offers specific benefits depending on the use case. Here’s a simplified comparison to help you decide:

Choose ABS if your project needs:

  • Lower material and processing costs
  • Good impact resistance at room temperature
  • Attractive surface finish with easy colouring options

Choose Polycarbonate if your project needs:

  • High heat resistance and mechanical strength
  • Optical clarity or transparency
  • Better performance under impact or stress

Real-world examples include ABS in products like LEGO bricks, printer housings, and car dashboards. Polycarbonate appears in protective screens, medical devices, and high-strength enclosures.

For projects requiring tight tolerances and high-performance plastics, Penta Precision offers a CNC machining service for plastic parts that ensures consistent, reliable outcomes.

Make the Best Choice for Your Project Now

Material selection has long-term implications for performance, cost, and manufacturability. ABS and PC both offer excellent benefits when matched correctly to application needs. Choosing wisely now will avoid production delays and part failure later.

If you’re developing a prototype or exploring short-run production, ABS is often the easier entry point. It’s especially effective in early design cycles due to its processability. This allows engineers to iterate faster while keeping production costs down.

For critical parts in aerospace, medical, or defence sectors, polycarbonate provides unmatched durability and heat resistance. If your application involves custom ABS parts, our precision plastic machining for abs components ensures the right fit and finish every time. This gives you confidence in long-term reliability and performance.

Explore more material comparisons: Aluminium vs Titanium, Delrin vs Nylon, and Plastic vs Metal.

ABS vs Polycarbonate: Which is Better for Your Application

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