ABS vs Polycarbonate (PC)
ABS and polycarbonate (PC) are both common engineering thermoplastics, but they sit at opposite ends of the toughness-versus-cost trade-off. The choice usually comes down to how much impact resistance and heat you actually need versus how much you want to spend and how easily the part has to be processed.
The verdict
Choose ABS for cost-sensitive, dimensionally stable cosmetic enclosures and parts that don't see high impact, heat, or load. Choose polycarbonate (PC) when you need extreme impact strength, optical clarity, or higher service temperatures and can accept the higher price and tougher processing. In short: ABS is the cheaper, easier-to-finish default; PC is the tough, transparent, heat-capable upgrade.
Side-by-side data
| Property | ABS | Polycarbonate (PC) |
|---|---|---|
| Category | Plastic | Plastic |
| Density (g/cm³) | 1.05 | 1.2 |
| Tensile strength (MPa) | 40 | 65 |
| Yield strength (MPa) | 40 | 62 |
| Elongation (%) | 10 | 110 |
| Hardness | R105 | R118 |
| Max service temp (°C) | 80 | 120 |
| Machinability | ●●●●● | ●●●●● |
| Corrosion resistance | ●●●●● | ●●●●● |
| Relative cost | ●●●●● | ●●●●● |
| Thermal cond. (W/m·K) | 0.17 | 0.2 |
| Typically used for | Prototypes, housings & consumer parts | Impact-resistant & optically clear parts |
Which should you choose?
Choose ABS if…
- The part is a cost-driven cosmetic enclosure, housing, or trim where moderate strength is enough.
- You want easy processing: it molds, 3D-prints (FDM), thermoforms, machines, and glues with solvent cement readily.
- You need a paintable, platable, or texturable surface for a finished consumer look.
- Impact loads, sustained heat (above ~80-90 C), and optical clarity are not requirements.
- You plan to chrome-plate or solvent-weld the part — ABS handles both well.
Choose Polycarbonate (PC) if…
- The part must survive high impact, drops, or near-unbreakable safety duty (guards, shields, helmets, glazing).
- You need optical transparency — lenses, light pipes, machine windows, or clear covers.
- Service temperature is high; PC holds up well above ABS's range.
- You need higher stiffness and load-bearing capability in a thin wall.
- Flame resistance or UL ratings matter — many PC grades are flame-retardant.
Key differences that matter
- Impact and toughness are the headline difference: PC is one of the toughest unfilled thermoplastics, while ABS offers only moderate impact resistance.
- Heat resistance favors PC — it stays usable at temperatures where ABS softens and creeps.
- ABS is cheaper, flows easier, and is far more forgiving to mold, machine, finish, and solvent-bond, making it the default for non-critical cosmetic parts.
- PC is naturally transparent while ABS is opaque, so any clear part essentially mandates PC (or a PC/ABS blend).
- Both have only fair outdoor/UV and chemical resistance — PC is notably attacked by many solvents and needs UV-stabilized grades for sustained sunlight.
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Open the Material SelectorGet a Quote →Frequently asked questions
Is ABS stronger than polycarbonate (PC)?
No. PC is significantly stronger and far tougher, especially in impact resistance and stiffness. ABS has respectable but moderate strength; PC is one of the most impact-resistant unfilled plastics available, which is why it's used for safety glazing and helmets.
Which is cheaper, ABS or PC?
ABS is cheaper, both in raw material cost and in processing. It flows more easily, molds faster, and is more forgiving, so total part cost is lower. PC carries a material premium plus higher processing temperatures and drying requirements.
Can I machine, weld, or glue both materials?
Both machine well, though PC's toughness can leave it gummy without sharp tooling and proper feeds. ABS solvent-welds and glues easily with cement; PC bonds best with adhesives or ultrasonic/heat welding. Neither is metal, so 'anodizing' doesn't apply — but ABS plates and paints especially well.
Which handles heat better?
Polycarbonate. PC keeps useful mechanical properties at notably higher temperatures, while ABS begins to soften and creep earlier. For anything near hot environments, enclosures around heat sources, or autoclaving, PC (or a PC blend) is the safer pick.
When should I use a PC/ABS blend instead?
Use a PC/ABS blend when you want most of PC's toughness and heat resistance but with easier molding, better surface finish, and lower cost than pure PC. It's common in automotive interiors, electronics housings, and parts that are both structural and cosmetic.
Property values are typical/nominal figures for early-stage guidance only and vary by temper, grade, supplier and heat treatment. Confirm critical specifications against a certified datasheet or with an mfgiq engineer before production.