How long does production tooling take?

Production hard tooling typically runs four to six weeks; bridge tooling can ship in 15 days.

Which material suits continuous high-temperature use?

PEEK and PPS are specified for continuous service at 250C and 220C respectively; PEI (Ultem) reaches an HDT of 217C.

Materials engineering · decades of experience

Choose the right material before you cut metal or tool a mold.

Compare 24 engineering plastics, metals and elastomers across six manufacturing processes. Review properties, relative cost and processing guidance, then get a production-ready recommendation from an engineer.

Explore 24 materials Get material advice

Engineer-reviewed selection · DFM feedback with every quote

Blue engineering polymer pellets representing raw manufacturing materials — **At a glance**Engineer-backed

Full profiles
24

Molding resins
36

Processes
6

Materials by process

Start with the process. Compare the grade.

Each profile shows a practical use case first, then opens to physical properties, relative cost and shop-floor processing guidance.

Showing all 24 materials

Aluminum 6061-T6

CNC Machining

General-purpose, weldable and easy to machine; ideal for housings, chassis and heat sinks.

General purposeLow costAnodizable

Density: 2.70 g/cm3
Tensile: 310 MPa
Hardness: 95 HB
Thermal Cond: 167 W/mK

Relative cost

MaterialLow

MachiningLow

Physical Properties
Property	Value
Density	2.70 g/cm3
Tensile Strength	310 MPa
Yield Strength	276 MPa
Elastic Modulus	68.9 GPa
Hardness	95 HB
Thermal Conductivity	167 W/mK

Application Guidance
Factor	Note
Best For	Chassis, brackets, housings, heat sinks
Avoid For	High-wear sliding (use 7075 or steel)
Corrosion Res.	Excellent (marine OK with anodize)
Weldability	Good (4043 filler wire)
Surface Finish	Excellent - Anodize Type II/III
Cost per kg	$8-12 USD

Engineer tip 6061-T6 machines at ~300% the speed of stainless steel. Use climb milling for best surface finish. Minimum wall: 0.5mm. For 50% higher strength, consider 7075-T6 (not weldable).

Stainless Steel 316L

CNC Machining

Excellent corrosion resistance for medical, marine and food-contact parts, with higher machining cost.

Medical gradeCorrosion resistantHigh machining cost

Density: 8.00 g/cm3
Tensile: 485 MPa
Hardness: 217 HB
Biocomp: ASTM F138

Relative cost

MaterialMed

MachiningHigh

Physical Properties
Property	Value
Density	8.00 g/cm3
Tensile Strength	485 MPa
Yield Strength	170 MPa
Elastic Modulus	193 GPa
Hardness	217 HB
Corrosion (salt)	Excellent

Application Guidance
Factor	Note
Best For	Medical implants, marine, food equipment
Avoid For	Weight-sensitive apps (use Ti or Al)
Weldability	Excellent (low carbon prevents sensitization)
Magnetic	No (austenitic, non-magnetic)
Surface Finish	Passivate > electropolish for medical
Cost per kg	$25-35 USD

Engineer tip 316L work-hardens rapidly - use sharp carbide inserts, low cutting speed (60-80 m/min). Passivation in citric acid for 20-30 min restores corrosion resistance. Min wall: 0.8mm.

Titanium Ti-6Al-4V (Gr5)

CNC Machining

High strength-to-weight and biocompatibility for aerospace and implants; costly to machine.

AerospaceMedicalExpensive

Density: 4.43 g/cm3
Tensile: 900 MPa
Hardness: 334 HB
Melt: 1665C

Relative cost

MaterialHigh

MachiningHigh

Physical Properties
Property	Value
Density	4.43 g/cm3
Tensile Strength	900 MPa (HT: 1100)
Yield Strength	880 MPa
Elastic Modulus	114 GPa
Hardness	334 HB
Melting Point	1665C

Application Guidance
Factor	Note
Best For	Aerospace, surgical implants, racing
Avoid For	Cost-sensitive consumer goods
Corrosion Res.	Excellent (saltwater, body fluid)
Weldability	Fair (requires inert atmosphere)
Surface	Anodize, PVD coating, passivate
Cost per kg	$80-150 USD

Engineer tip Titanium has poor thermal conductivity - heat concentrates at the cutting edge. Use rigid setups, high-pressure coolant (70+ bar), sharp carbide. Min wall: 1.0mm. Critical: chip evacuation to avoid fire.

Delrin (POM-C)

CNC Machining - Plastic

Low-friction, dimensionally stable plastic for gears, bearings and conveyor components.

Low frictionDimensionally stable

Density: 1.41 g/cm3
Tensile: 70 MPa
HDT: 136C
Friction: 0.15-0.35

Relative cost

MaterialLow

MachiningLow

Physical Properties
Property	Value
Density	1.41 g/cm3
Tensile Strength	70 MPa
Flexural Modulus	2.9 GPa
HDT @ 1.8MPa	136C
Friction Coeff.	0.15-0.35 (self-lub)
Water Absorption	0.2%

Application Guidance
Factor	Note
Best For	Gears, bearings, conveyor components
Avoid For	Strong acids/bases (pH 9)
vs Metal	1/7 weight of steel, 1/3 of Al
Adhesion	Difficult to bond (use mechanical)
Surface	Polishes to mirror; no coating needed
Cost per kg	$6-10 USD

Engineer tip POM machines beautifully but chips can be stringy. Use sharp HSS or carbide. Min wall: 0.8mm. Avoid thin walls over large spans - POM creeps under sustained load above 60C. Copolymer (POM-C) is more chemical-resistant than homopolymer (POM-H).

PEEK

CNC Machining - Plastic

High-temperature, chemical-resistant performance for seals, bearings and demanding medical or aerospace parts.

High tempExpensiveMedical

Density: 1.32 g/cm3
Tensile: 100 MPa
HDT: 160C
Max Use: 250C

Relative cost

MaterialHigh

MachiningHigh

Physical Properties
Property	Value
Density	1.32 g/cm3
Tensile Strength	100 MPa
Flexural Modulus	3.9 GPa
HDT @ 1.8MPa	160C
Continuous Use	250C
Flammability	V-0 @ 1.5mm

Application Guidance
Factor	Note
Best For	Bearings, seals, medical implants, aerospace
Avoid For	Cost-sensitive consumer applications
Chemical Res.	Excellent (acids, bases, organics)
vs 6061 Al	70% lighter, similar stiffness
Sterilization	Gamma stable, autoclavable
Cost per kg	$300-600 USD

Engineer tip Anneal PEEK before machining to relieve stress. Use carbide or ceramic inserts. Min wall: 1.5mm. 30% glass-filled PEEK improves wear resistance but is more abrasive. Always use coolant - PEEK generates significant heat.

Black ABS injection molded grille components produced by BAOLAIHUA

ABS

Injection Molding - Rigid

Tough, low-cost and easy to finish; suited to housings, trim and cosmetic parts.

Low costPaintableMust dry

Density: 1.04 g/cm3
Tensile: 45 MPa
HDT: 88C
Shrink: 0.5-0.7%

Relative cost

MaterialLow

MoldingLow

Physical Properties
Property	Value
Density	1.04 g/cm3
Tensile Strength	45 MPa
Flexural Modulus	2.3 GPa
HDT @ 1.8MPa	88C
Impact (Izod)	200-400 J/m
Melt Temp	200-240C

Molding Guidance
Factor	Note
Best For	Housings, toys, automotive trim
Mold Temp	50-80C
Drying	2-4 hrs @ 80C (critical!)
Gate Design	Edge or submarine gate
Surface	Paint, plate, vacuum metalize
Cost per kg	$2.50-4 USD

Engineer tip ABS must be dried before molding - undried resin causes silver streaks and weak weld lines. Wall: 1.2-3.5mm. Draft: 0.5 min. Avoid sections over 5mm thick to prevent sink. UV-resistant grades available for outdoor use.

Polypropylene (PP)

Injection Molding - Rigid

Lowest-cost, food-safe resin with excellent chemical resistance; design around high shrinkage.

Lowest costFood safeHigh shrinkage

Density: 0.90 g/cm3
Tensile: 35 MPa
HDT: 100C
Shrink: 1.0-2.5%

Relative cost

MaterialLowest

MoldingLow

Physical Properties
Property	Value
Density	0.90 g/cm3
Tensile Strength	35 MPa
Flexural Modulus	1.4 GPa
HDT @ 1.8MPa	100C (homopolymer)
Impact (Izod)	20-60 J/m
Melt Temp	180-230C

Molding Guidance
Factor	Note
Best For	Packaging, hinges, automotive, medical
Mold Temp	40-80C
Warning	High shrink (1-2.5%) - gate carefully
Living Hinge	Yes - 0.2-0.5mm flexure
Chemical Res.	Excellent (acids, bases)
Cost per kg	$1.50-2.50 USD

Engineer tip PP's high shrinkage requires careful gate placement and cooling design. Use copolymer PP for better low-temp impact. 20-40% glass-filled PP improves stiffness and reduces shrink to 0.5-1.0%. Min wall: 0.8mm. Draft: 1 minimum.

Polycarbonate (PC)

Injection Molding - Rigid

Transparent, high-impact strength for safety lenses, lighting and medical housings.

TransparentHigh impactStress cracks

Density: 1.20 g/cm3
Tensile: 70 MPa
HDT: 138C
LT: 88% transparent

Relative cost

MaterialMed

MoldingMed

Physical Properties
Property	Value
Density	1.20 g/cm3
Tensile Strength	70 MPa
Flexural Modulus	2.3 GPa
HDT @ 1.8MPa	138C
Light Transmission	88-90%
Impact (Izod)	800-900 J/m

Molding Guidance
Factor	Note
Best For	Safety glasses, medical, lighting
Mold Temp	80-120C (high temp required)
Warning	Prone to stress cracking
Drying	3-4 hrs @ 120C
vs Acrylic	Stronger impact but lower clarity
Cost per kg	$4-7 USD

Engineer tip PC requires high mold temps (80-120C) for optical clarity and minimal residual stress. Avoid sharp internal corners - min radius: 0.5mm. Wall: 1.5-4mm. UV-stabilized grades essential for outdoor use.

Nylon 6 (PA6)

Injection Molding - Engineering

Tough, wear-resistant nylon for gears and structural parts; moisture pickup affects dimensions.

ToughWear resistantAbsorbs moisture

Density: 1.13 g/cm3
Tensile: 80 MPa
HDT: 65C
Shrink: 0.8-1.5%

Relative cost

MaterialMed

MoldingMed

Physical Properties
Property	Value
Density	1.13 g/cm3
Tensile Strength	80 MPa
Flexural Modulus	2.6 GPa
HDT @ 1.8MPa	65C
Impact (Izod)	50-120 J/m
Melt Temp	220-260C

Molding Guidance
Factor	Note
Best For	Gears, bearings, structural parts, cable ties
Mold Temp	60-100C
vs PA66	Easier molding, lower HDT, more ductile
Moisture	Absorbs 3% (conditions parts at 50% RH)
GF Grades	15-50% glass fiber available
Cost per kg	$4-7 USD

Engineer tip PA6 is more forgiving than PA66 for molding. Must be dried 4+ hours at 80C. 30% glass-filled PA6 doubles stiffness and halves shrinkage. Min wall: 0.8mm. Excellent for snap-fits due to high elongation.

PBT

Injection Molding - Engineering

Stable electrical and dimensional performance for connectors, switches and automotive components.

ElectricalLow moistureAutomotive

Density: 1.31 g/cm3
Tensile: 55 MPa
HDT: 60-150C
Shrink: 0.5-2.0%

Relative cost

MaterialMed

MoldingLow

Physical Properties
Property	Value
Density	1.31 g/cm3
Tensile Strength	55 MPa
Flexural Modulus	2.3 GPa
HDT @ 1.8MPa	60-150C (GF dependent)
Water Absorption	0.08% (excellent)
Melt Temp	230-270C

Molding Guidance
Factor	Note
Best For	Electrical connectors, switches, auto parts
Mold Temp	60-100C
vs PA66	Lower moisture absorption, better electrical
Flame Retardant	V-0 grades readily available
GF Grades	10-40% glass fiber common
Cost per kg	$5-9 USD

Engineer tip PBT crystallizes quickly enabling fast cycle times. Often blended with PET (PBT+PET) for improved surface appearance. Must be dried 2-4 hrs at 120C. Sharp corners stress-crack with certain chemicals. Min wall: 0.8mm.

PMMA (Acrylic)

Injection Molding - Transparent

Optically clear and UV-stable for lenses, displays and signage; more brittle than PC.

92% transparentUV stableBrittle

Density: 1.19 g/cm3
Tensile: 70 MPa
LT: 92%
HDT: 95C

Relative cost

MaterialMed

MoldingMed

Physical Properties
Property	Value
Density	1.19 g/cm3
Tensile Strength	70 MPa
Flexural Modulus	3.2 GPa
HDT @ 1.8MPa	95C
Light Transmission	92%
Impact (Izod)	15-20 J/m (brittle)

Molding Guidance
Factor	Note
Best For	Displays, signage, lighting diffusers, lenses
Mold Temp	60-80C
vs PC	Better clarity, lower impact, cheaper
Drying	3-4 hrs at 80C
UV Stability	Excellent - ideal for outdoor use
Cost per kg	$3-5 USD

Engineer tip PMMA requires highly polished molds for optical clarity. Gate into thickest section to avoid flow marks. Highly notch-sensitive - all corners must have generous radii (>0.5mm). Impact-modified grades available but reduce clarity to 85%.

HDPE / LDPE

Injection Molding / Blow Molding

Low-cost, food-safe and recyclable for containers and pipes; high shrinkage needs careful design.

Lowest costFood safeRecyclable

HDPE Density: 0.95 g/cm3
LDPE Density: 0.92
HDPE Tensile: 32 MPa
HDT: 75-120C

Relative cost

MaterialLowest

MoldingLow

HDPE vs LDPE
Property	Value
Density	0.95 g/cm3 0.92
Tensile	32 MPa 10-20 MPa
Stiffness	Rigid Flexible
HDT	75-120C 40-50C
Process	Injection / Blow Film / Blow
Chemical Res.	Excellent Good

Molding Guidance
Factor	Note
Best For	Bottles (blow molding), containers, pipes, extrusion profiles, toys
Mold Temp	20-60C
Shrinkage	1.5-4% (high! design for it)
Drying	Generally not required
UV	Black HDPE has built-in UV stability
Cost per kg	$1.20-2 USD

Engineer tip HDPE shrinkage is very high (1.5-4%) - parts continue to shrink for days after molding. Design gates at thickest sections with generous draft (2-3 degrees). HDPE is the #1 recycled plastic globally. Min wall: 0.8mm. Blow molding is ideal for bottles and hollow parts.

PS / HIPS

Injection Molding - Commodity

Very low-cost material for packaging and housings; GPPS is clear but brittle, while HIPS adds toughness.

Very low costClear (GPPS)Brittle (GPPS)

Density: 1.04-1.06
Tensile: 25-45 MPa
HDT: 70-95C

Relative cost

MaterialLowest

MoldingLow

Physical Properties
Property	Value
Density	1.04 g/cm3 1.06
Tensile	45 MPa 25 MPa
Impact	15 J/m (brittle) 100-150 J/m
Transparent	Yes (88%) Opaque
HDT	95C 70-85C
Melt Temp	180-260C 180-240C

Molding Guidance
Factor	Note
Best For	Packaging, cups, appliance housings
Mold Temp	20-60C (low!)
vs ABS	Cheaper but lower impact and HDT
Flame Retardant	HB rating standard; V-2 possible
UV Resistance	Poor - yellows in sunlight
Cost per kg	$1.30-2.50 USD

Engineer tip PS is one of the easiest plastics to mold with very fast cycle times. GPPS is crystal clear but brittle - do not use for load-bearing parts. HIPS is opaque but much tougher. Both are excellent for thermoforming. Min wall: 0.8mm. Draft: 1-2 degrees.

AS (SAN)

Injection Molding - Transparent

Transparent, chemical-resistant and economical for cosmetic packaging and household parts.

TransparentChemical res.Low cost

Density: 1.08 g/cm3
Tensile: 75 MPa
LT: 88%
HDT: 100C

Relative cost

MaterialLow

MoldingLow

Physical Properties
Property	Value
Density	1.08 g/cm3
Tensile Strength	75 MPa
Flexural Modulus	3.8 GPa
HDT @ 1.8MPa	100C
Light Transmission	88%
Hardness (Rockwell)	115 M

Molding Guidance
Factor	Note
Best For	Cosmetic packaging, household items, cups
Mold Temp	40-80C
vs PMMA	Better chemical resistance, cheaper
vs PC	Lower impact but easier to mold
Blending	Often blended with ABS (AS+ABS)
Cost per kg	$2-3.50 USD

Engineer tip SAN is a cost-effective alternative to PMMA when chemical resistance matters more than maximum clarity. Often used in blends with ABS to improve transparency and surface hardness. Must be dried before molding. Min wall: 0.8mm. Good for thin-wall applications.

PVC (Rigid / Flexible)

Injection Molding / Extrusion

Flame-retardant and chemical-resistant for pipes, profiles and wire insulation; requires heat stabilization.

Low costFlame retardantRequires stabilizer

Density: 1.35-1.45
Tensile: 40-55 MPa
HDT: 55-80C
LOI: 45%+

Relative cost

MaterialLow

MoldingMed

Physical Properties
Property	Value
Density	1.35-1.45 1.15-1.35
Tensile	40-55 MPa 10-25 MPa
Hardness	80-85 Shore D 50-95 Shore A
HDT	55-80C <40C
LOI	45%+ 25-35%
Flammability	Self-extinguishing Slow burning

Molding Guidance
Factor	Note
Best For	Pipes, fittings, tubing, profiles, wire insulation
Mold Temp	30-60C
Decomposition	Releases HCl above 200C - use stabilizer
Heat Stabilizer	Required (tin, calcium/zinc based)
Plasticizer	Phthalates or bio-based alternatives
Cost per kg	$1.20-2.50 USD

Engineer tip PVC degrades above 200C releasing hydrochloric acid. Always use heat stabilizers. Rigid PVC has the highest LOI (oxygen index) of commodity plastics making it naturally flame retardant. Corrosive to molds - use chrome-plated or stainless steel molds. Min wall: 1.0mm.

PPS

Injection Molding - High Performance

High-temperature, chemical-resistant engineering resin for under-hood electrical and pump housings.

220C continuousChemical proofExpensive

Density: 1.35 g/cm3
Tensile: 85 MPa (GF40)
HDT: 260C (GF40)
Max Use: 220C

Relative cost

MaterialHigh

MoldingHigh

Physical Properties
Property	Value
Density	1.35 g/cm3 (GF40)
Tensile Strength	85 MPa (GF40)
Flexural Modulus	11.5 GPa (GF40)
HDT @ 1.8MPa	260C (GF40)
Max Continuous	220C
Flammability	V-0 @ 0.4mm

Molding Guidance
Factor	Note
Best For	Under-hood electrical, pump housings
Mold Temp	130-150C (high!)
Chemical Res.	Excellent - virtually all solvents
GF Content	Almost always 30-40% glass filled
vs PEEK	Lower cost, lower ductility
Cost per kg	$15-30 USD

Engineer tip PPS is almost always used with 30-40% glass fiber. Unfilled PPS has limited use. Requires very high mold temperatures (130-150C) for crystallization. Poor weld line strength - design to avoid. Excellent for SMT reflow (260C peak) connectors. Min wall: 0.8mm.

PPSU

Injection Molding - Medical Grade

Impact-resistant and autoclavable for surgical instruments and reusable medical trays.

AutoclavableImpact resistantVery expensive

Density: 1.29 g/cm3
Tensile: 75 MPa
HDT: 207C
Autoclave: 1000+ cycles

Relative cost

MaterialHigh

MoldingHigh

Physical Properties
Property	Value
Density	1.29 g/cm3
Tensile Strength	75 MPa
Flexural Modulus	2.4 GPa
HDT @ 1.8MPa	207C
Notched Izod	690 J/m (exceptional)
Steam Sterilization	1000+ cycles @ 134C

Molding Guidance
Factor	Note
Best For	Surgical instruments, sterilization trays
Mold Temp	150-180C
vs PEI	Better impact and hydrolysis resistance
Biocompatible	ISO 10993, USP Class VI
Transparent	Amber tint (inherent color)
Cost per kg	$50-100 USD

Engineer tip PPSU's notch impact strength (690 J/m) is among the highest of any thermoplastic. It survives repeated steam sterilization where PEI and PES would crack. Natural amber color cannot be changed to water-clear. Mold at 150-180C for proper flow. Min wall: 1.0mm.

EVA

Injection / Foam / Extrusion

Soft, flexible and foam-capable for shoe soles, tubing and protective parts; limited heat resistance.

SoftLow costLow temp flex

Density: 0.92-0.95
Hardness: Shore A 40-95
VA Content: 5-40%

Relative cost

MaterialLow

MoldingLow

Physical Properties
Property	Value
Density	0.92-0.95 g/cm3
Hardness	Shore A 40-95
Tensile Strength	5-25 MPa
Elongation	500-1000%
Service Temp	-70 to 65C
VA Content Effect	Higher VA = softer, more flexible

Molding Guidance
Factor	Note
Best For	Shoe soles, foam, tubing, toys
Mold Temp	20-50C
Foam Grades	Cross-linked for foam expansion
vs TPE	Cheaper but not as overmoldable
UV Resistance	Good - outdoor use OK
Cost per kg	$2-4 USD

Engineer tip VA (vinyl acetate) content determines properties: 5-10% VA is stiff like LDPE; 18-28% is flexible like rubber; 33-40% is adhesive-grade. Cross-linked EVA foam (by peroxide or radiation) creates the lightweight cushioning in shoe midsoles. Min wall: 1.0mm.

POE

Injection Molding - Toughener

Tough impact modifier for bumpers and flexible parts; usually blended with PP or PE.

Impact modifierLow tempTough

Density: 0.86-0.91
Hardness: Shore A 60-95
Tensile: 5-25 MPa

Relative cost

MaterialMed

MoldingLow

Physical Properties
Property	Value
Density	0.86-0.91 g/cm3 (very light)
Hardness	Shore A 60-95
Tensile Strength	5-25 MPa
Elongation	500-1500%
Service Temp	-60 to 80C
Notched Izod	Does not break (no notch sensitivity)

Molding Guidance
Factor	Note
Best For	Impact modifier, flexible parts, bumpers
Mold Temp	20-60C
Toughening	Add 5-20% to PP/PA for impact
vs EPDM	Better flow, no peroxide needed
Recycling	Fully recyclable with PO base
Cost per kg	$3-6 USD

Engineer tip POE is primarily used as an impact modifier rather than a standalone material. Adding 10-20% POE to PP dramatically improves low-temperature impact while maintaining stiffness. Unlike EPDM rubber, POE can be processed on standard thermoplastic equipment without vulcanization. Min wall: 0.8mm.

TPE (SBC/TPV)

Injection Molding - Elastomer

Flexible and overmoldable for grips and seals; recyclable and suited to soft-touch parts.

RecyclableOvermoldableLow cost

Density: 0.89-1.15
Hardness: Shore A 20-90
Elongation: 200-500%

Relative cost

MaterialMed

MoldingMed

Physical Properties
Property	Value
Density	0.89-1.15 g/cm3
Hardness	Shore A 20-90
Tensile Strength	3-25 MPa
Elongation @ Break	200-500%
Compression Set	15-50%
Service Temp	-50 to 135C

Molding Guidance
Factor	Note
Best For	Soft grips, seals, overmolding
Overmold Substrates	PP (excellent), ABS (good)
Mold Temp	30-60C
vs LSR	Cheaper but lower temp resistance
Recycling	Fully recyclable
Cost per kg	$4-10 USD

Engineer tip For overmolding, substrate must be clean. Bond strength depends on Shore A - softer TPE (<50A) bonds better but is harder to eject. Overmold thickness: 1.0-3.0mm. Include undercuts or mechanical anchors for critical bonds.

Liquid Silicone Rubber (LSR)

Injection Molding - Elastomer

Biocompatible, heat-resistant silicone for medical devices and seals; needs dedicated liquid-silicone molding.

BiocompatibleHigh tempExpensive

Density: 1.10-1.50
Hardness: Shore A 10-80
Max Temp: 230C

Relative cost

MaterialHigh

MoldingHigh

Physical Properties
Property	Value
Density	1.10-1.50 g/cm3
Hardness	Shore A 10-80
Tensile Strength	5-12 MPa
Elongation	300-800%
Compression Set	<15% (excellent)
Service Temp	-60 to 230C

Molding Guidance
Factor	Note
Best For	Medical devices, baby products, seals
Cure System	Platinum (addition cure)
Equipment	Requires LSR metering system
Biocompatible	ISO 10993, USP Class VI
Sterilization	Autoclave, gamma, EtO
Cost per kg	$20-50 USD

Engineer tip LSR molds run cold (10-30C) with heated cavities. Cold runner systems reduce waste by 95% vs traditional runners. Flash is common - design 0.02-0.05mm venting. LSR flows exceptionally well - walls as thin as 0.2mm possible.

SLA Resins

3D Printing - Photopolymer

Smooth, high-detail resin for visual prototypes and fit checks before production tooling.

Smooth surfaceFine detailFast

Layer: 25-100 um
Tolerance: +/-0.1mm
Ra: 1-3 um

Relative cost

MaterialMed

Part CostMed

Resin Types
Type	Key Property
Standard	Good detail, general purpose
Tough/Durable	Impact resistant, PP-like
High Temp	HDT 230-290C
Flexible	Shore A 30-90
Castable	Zero ash for investment casting
Biocompatible	USP Class VI (limited)

Application Guidance
Factor	Note
Best For	Visual prototypes, fit checks
Limitation	UV degradation outdoors
Post-Cure	Required for full properties
Support Marks	Visible on bottom surfaces
Max Dimension	~300 x 300 x 400mm
Cost per liter	$50-200 USD

Engineer tip SLA parts require isotropic UV post-cure to achieve datasheet properties. Without post-cure, strength is 40-60% lower. Design supports carefully - they leave witness marks. Min wall: 0.8mm. Holes <1mm may close during printing.

SLS Nylon (PA12)

3D Printing - Powder Bed Fusion

Durable, support-free nylon for functional brackets, ducts and complex geometries.

No supportsDurableComplex geometry

Layer: 100 um
Tensile: 48 MPa
Elongation: 15-20%

Relative cost

MaterialMed

Part CostMed

Physical Properties
Property	Value
Density	0.98-1.01 g/cm3
Tensile Strength	48 MPa
Flexural Modulus	1.65 GPa
Elongation @ Break	15-20%
Impact (Izod)	35 J/m
Service Temp	Up to 115C

Application Guidance
Factor	Note
Best For	Functional prototypes, brackets, ducts
Supports	None needed (self-supporting)
Surface	Slightly grainy (bead blast to improve)
Dyeing	Can be dyed various colors
vs MJF PA12	SLS has better surface; MJF faster
Cost per kg	$60-100 USD

Engineer tip SLS PA12 has a slightly porous surface that absorbs moisture. Seal with epoxy or vapor smoothing for watertight applications. Glass-filled PA12 (PA12-GF) increases stiffness by 40% but reduces impact. Min wall: 0.7mm. Max unsupported overhang: 45 degrees.

Sheet Metal (Al/Steel/SS)

Laser Cutting, Bending, Stamping

Laser-cut, formed and finished aluminum, steel or stainless steel for durable enclosures and brackets.

AluminumSteelPowder CoatAnodize

Thickness: 0.5-10mm
Tolerance: +/-0.1mm
Max Size: 1500x3000mm

Relative cost

MaterialLow

FabricationMed

Material Options
Property	Value
Aluminum 5052-H32	228 MPa $6-10
Cold Rolled Steel 1018	440 MPa $2-4
Stainless Steel 304	515 MPa $8-15
Copper C110	220 MPa $10-18
Galvanized Steel	270 MPa $3-5

Fabrication Capabilities
Process	Capability
Laser Cutting	+/-0.1mm tolerance, up to 25mm
CNC Bending	Up to 8-axis, +/-0.2 deg
Stamping	Progressive dies, high volume
Welding	TIG, MIG, spot welding
Hardware	PEM inserts, rivets
Finishing	Anodize, powder coat, plating

Engineer tip Minimum bend radius = material thickness (1T) for soft aluminum, 2T for steel. For holes near bends, keep distance > 2 x thickness + bend radius. Standard K-factor: 0.44 for Al, 0.42 for steel. Design bend relief notches to prevent tearing.

Quick comparison

Commonly specified plastics at a glance

Benefits, typical applications and the processing constraint worth knowing before you commit to tooling.

Commonly specified plastics: benefits, applications and processing notes
Material	Key benefits	Best applications	Processing notes
PP	Inexpensive, chemical resistant, flexible, food-safe	Packaging, hinges, automotive	Shrinks 1-2.5%; warps easily
ABS	High impact, low cost, easy finish, paintable	Housings, toys, automotive trim	Must dry 2-4hrs @ 80C
PC	Highest impact (transparent), HDT 138C	Safety glasses, medical, lighting	High mold temp 80-120C req.
PC-ABS	PC strength + ABS processability	Electronics, handheld devices	Vulnerable to solvents
PA66	Strong, wear/fatigue resistant	Gears, bearings, connectors	Absorbs 2.5% moisture
POM	High stiffness, low friction, self-lub	Precision gears, sliding parts	Prone to warping
PEEK	Continuous use 250C, biocompatible	Aerospace, medical implants	Very expensive; heated mold >150C
PEI (Ultem)	HDT 217C, flame retardant V-0	Medical, aircraft interiors	Very expensive
TPE	Flexible, recyclable, overmoldable	Grips, seals, overmolding	Lower temp resistance
TPU	Abrasion resistant, oil resistant	Footwear, tubing, wheels	Hygroscopic; pricey
LSR	Heat resistant 230C, biocompatible	Medical, baby products, seals	Requires LSR molding system
PA6	Tough, wear resistant, easier than PA66	Gears, cable ties, structural	Absorbs 3% moisture
PBT	Low moisture, excellent electrical	Connectors, switches, auto	Stress cracks with chemicals
PMMA	92% transparent, UV stable	Displays, signage, lenses	Brittle - notch sensitive
HDPE/LDPE	Lowest cost, food safe, recyclable	Bottles, containers, pipes	Very high shrinkage 1.5-4%
PS/HIPS	Very low cost, clear (GPPS)	Packaging, cups, appliances	Brittle (GPPS); UV degrades
AS (SAN)	Transparent, chemical resistant	Cosmetic packaging, household	Lower impact than PMMA/PC
PVC	Flame retardant, chemical resistant	Pipes, fittings, wire insulation	Decomposes >200C (HCl gas)
PPS	220C continuous, chemical proof	Under-hood electrical, pumps	Almost always needs GF
PPSU	Autoclavable 1000+, high impact	Surgical instruments, trays	Very expensive; amber color
EVA	Soft, flexible, foam capable	Shoe soles, foam, tubing	Low HDT; not for high temps
POE	Impact modifier, super tough	Bumper modifiers, flexible parts	Usually blended, not standalone

Processing guide

Parameters that decide whether a part succeeds

Six rules that prevent most molding failures, plus the fillers and modifiers engineers reach for.

PP shrinks 1-2.5% - design gates and cooling carefully to minimize warping

ABS is hygroscopic - must dry 2-4 hrs @ 80C before molding

PC requires mold temp 80-120C to avoid stress cracking

Nylon absorbs moisture (up to 2.5%) - post-mold conditioning needed

PEEK demands heated molds >150C , specialized screws, controlled cooling

Glass-filled resins shrink less but increase mold wear 3-5x

Glass Fiber (10-40%)

Increases tensile strength, stiffness and HDT. Makes resin more brittle and abrasive to molds.

Carbon Fiber (10-30%)

Superior stiffness-to-weight. ESD safe. Higher cost than glass. Excellent for structural parts.

Mineral Fillers (Talc, Clay)

Reduces cost, increases hardness and dimensional stability. Lower shrinkage than pure resin.

PTFE / MoS2 (5-15%)

Self-lubricating for bearing/sliding apps. Reduces friction coefficient from 0.4 to 0.1.

UV Stabilizers (1-3%)

Essential for outdoor use. HALS and UV absorbers prevent degradation from sunlight.

Flame Retardants

Brominated or halogen-free phosphorus-based. Achieves UL 94 V-0 at 0.8mm.

Certifications

Grades matched to your regulatory requirement

Every program runs inside our ISO 9001 and IATF 16949 quality system.

Aerospace - AS9100D

PEEK, Ultem, Titanium Gr5, Al 7075. Heat and flame resistance for cabin and engine components.

PEEKTi-6Al-4VAl 7075

Medical - ISO 13485 workflow

Titanium, PEI, PPSU, LSR. Biocompatible per ISO 10993, sterilizable, chemically resistant.

TitaniumPEILSR

Electronics - UL / RoHS

ABS-FR, PC-ABS, Copper. EMI shielding, electrical insulation, UL 94 V-0 flame retardancy.

ABS-FRPC-ABSCopper

Automotive - IATF 16949

PP, PA66-GF, PBT, TPV. Heat resistant, chemically stable for under-hood and interior.

PPPA66-GFPBT

Food & Beverage - FDA

PP, HDPE, LSR, SS 316L. FDA 21 CFR compliant, chemically resistant, easy to clean.

PPHDPESS316L

Marine & Offshore

Titanium Gr2, SS 316L, Cu-Ni 90/10. Outstanding corrosion resistance in saltwater.

Ti Gr.2SS316LCu-Ni

Surface finish

SPI mould finish and post-processing standards

What the texture on the tool becomes on the finished part.

Aluminum and stainless steel surface roughness examples from Ra 0.8 to Ra 0.1

Anodised aluminium parts in several colours

SPI mould finish grades

A high-gloss mould finish does not guarantee a glossy part. Final appearance depends on resin, moulding conditions and geometry — amorphous resins (PC, ABS) reproduce texture better than semi-crystalline ones (PP, PA).

ASPI A-1 to A-3 · - Diamond buff, mirrorRa < 0.10 um

BSPI B-1 to B-3 · - Fine grit, semi-glossRa 0.10-0.30 um

CSPI C-1 to C-3 · - Matte stone finishRa 0.30-0.80 um

DSPI D-1 to D-3 · - Textured/satinRa 0.80-3.00 um

MAs-Machined · - Tool marks visibleRa 3.2-6.3 um

Post-processingBead blasting · Anodizing (Type II/III) · Electro-polishing · Chrome/Nickel plating · Vapor polishing (PC/acrylic) · Powder coating · Laser marking · PVD coating · Chem film (Alodine) · Passivation

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Send us the duty cycle, operating temperature, chemical exposure and annual volume. An engineer replies within one business day with a recommendation and a DFM note.

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