Polycarbonate vs ABS: Selecting the Right Plastic for Strength, Impact, and Design
Material selection directly influences how a product performs, appears, and endures over time. Polycarbonate and ABS are both widely used in injection moulding, yet they serve distinct engineering priorities.
While ABS is often associated with balanced performance and cost efficiency, polycarbonate is recognised for exceptional toughness and optical clarity. Understanding these differences helps product teams align material choice with functional and design requirements.
Material Overview
Polycarbonate (PC)
Polycarbonate is an engineering thermoplastic valued for its outstanding impact resistance, transparency, and thermal stability. It is frequently specified in applications where durability and visibility are critical.
ABS (Acrylonitrile Butadiene Styrene)
ABS offers reliable strength, good dimensional stability, and excellent surface finish. Its processing consistency makes it a versatile choice across many industries.
Key Property Comparison
| Property | Polycarbonate | ABS |
|---|---|---|
| Impact Resistance | Exceptional | Very good |
| Transparency | Natural clarity | Opaque |
| Heat Resistance | Higher | Moderate |
| Surface Finish | Good | Excellent |
| Processability | More demanding | Generally easier |
| Cost | Higher | Typically lower |
When Polycarbonate Is Often the Better Choice
- High-impact environments
- Transparent components
- Protective housings
- Applications requiring thermal stability
When ABS Makes More Sense
- Consumer-facing products
- Applications prioritising surface quality
- Cost-sensitive programs
- Parts requiring predictable processing
Processing Considerations
Polycarbonate typically requires tighter process control due to its thermal characteristics. ABS is often considered more forgiving, which can support stable production in a broader range of environments.
Cost vs Performance Should Be Evaluated Together
Although polycarbonate carries a higher material cost, its mechanical advantages may reduce long-term risk in demanding applications.
The most economical material is usually the one that meets performance requirements without unnecessary over-specification.
Design Requirements Should Lead the Decision
Material selection is most effective when evaluated alongside geometry, tolerances, environmental exposure, and lifecycle expectations.
Early collaboration with manufacturing specialists helps prevent expensive redesigns later.
Frequently Asked Questions
Is polycarbonate stronger than ABS?
Polycarbonate typically delivers superior impact resistance.
When should ABS be chosen instead?
When cost efficiency, surface finish, and processing stability are key priorities.
Can polycarbonate be transparent?
Yes — it is naturally clear and widely used where visibility is required.