ABS and polycarbonate are both tough thermoplastics used in enclosures, housings, and consumer products. ABS is cheap, easy to mold, paintable. PC is tough, transparent, and heat-resistant. This guide covers when each is right, the ABS/PC blend that often beats either alone, and why most consumer electronics use one specifically.
| Property | ABS | PC | PC/ABS blend |
|---|---|---|---|
| Tensile strength | 42 MPa | 65 MPa | 52 MPa |
| Impact strength (notched) | 215 J/m | 900 J/m | 550 J/m |
| Heat deflection (1.8 MPa) | 90 °C | 130 °C | 105 °C |
| Max continuous service temp | 80 °C | 120 °C | 100 °C |
| Transparency | Opaque | Transparent (90% visible light) | Opaque |
| UV stability | Poor (yellows outdoors) | Moderate (better with UV-stab grade) | Moderate |
| Flammability (UL 94) | HB (burns) | V-2 (natural), V-0 grades available | V-0 grades available |
| Cost (per kg) | ~$2.50 | ~$5.00 | ~$4.00 |
| Injection molding ease | Excellent | Harder (higher temp, drying critical) | Good |
Toys, appliances, interior trim. ABS costs half of PC with adequate properties for most applications.
ABS takes paint and adhesives readily. PC is harder to paint without specific primers. For painted housings, ABS is the default.
ABS is the standard substrate for chrome-plated plastic parts (automotive trim, bathroom fixtures). PC doesn't plate as reliably.
ABS has excellent flow and low shrinkage. Tight-tolerance mold geometry with thin walls is more forgiving in ABS than PC.
ABS yellows in UV — avoid outdoor. Indoor use has no issue. Most enclosures, housings, consumer goods.
Safety glasses, helmets, machine guards. PC has 4× the impact strength of ABS. Used where a part must survive drop or impact.
Lenses, light fixtures, display covers. PC is the transparent engineering plastic (above acrylic for impact; below glass for optics).
PC continuous to 120 °C. ABS limited to 80 °C. For near-boiling water or light heating service, PC only.
UV-stabilized PC yellows less than ABS outdoors. For electrical enclosures, outdoor signage, exterior lenses — PC.
PC available in UL 94 V-0 grades. ABS only HB (burns). For code-compliant electrical housings, PC is the practical choice.
PC/ABS blend combines benefits: stiffness and heat resistance of PC, cost and processability of ABS. Popular for:
Typical PC/ABS blend ratios: 60/40 (high-PC, higher strength) to 30/70 (high-ABS, more economical). Branded as Cycoloy, Bayblend, Xenoy — same general class.
When you see a laptop housing that feels stiffer and more premium than ABS but isn't quite PC, it's almost certainly a PC/ABS blend. Most major consumer electronics landed on this formulation in the 2000s and haven't moved.
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