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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.
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.
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.
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.
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.
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 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.
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.
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:
Choose Polycarbonate if your project needs:
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.
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.
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