Plastic Playbook: Choosing The Right Polymer
Choosing the right polymer for your plastic parts can significantly impact the success of your product. In this episode, Adrian and Paul Adams from Sofeast explore the most common polymers used in manufacturing, from everyday workhorses like ABS to high-performance engineering plastics and sustainable bioplastics.
They cover the strengths, weaknesses, and real-world applications of each group, plus share a cautionary case study where a material change led to product failure. The episode wraps up with advice on additives, testing, and key considerations to ensure your material choice supports your product’s success.
Episode Sections:
00:00 – Introduction
00:55 – Why Polymer Selection Matters
04:49 – ABS and Its Blends – The Workhorse Polymer
08:27 – Commodity Polymers – PP, PC, HDPE
16:20 – Engineering Polymers – Nylon, POM, PCTG
26:19 – Case Study: A Costly Material Change
32:42 – Flexible & Sustainable Options
38:42 – Key Additives and Modifiers
40:17 – Wrap-Up and Key Takeaways
Need help choosing the right polymer for your product? Contact us for a conversation.
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Polymer Selection Guide: Summary Table
Polymer Family
Key Strength & "Personality"
Typical Tensile
Strength (MPa)
Typical Impact
(Izod, J/m)
Key Limitations
Best For Applications Like...
COMMODITY / WORKHORSE POLYMERS
PP (Polypropylene)
The Low-Cost Champion
25 - 40
20 - 80
Poor UV resistance, difficult to bond, can be brittle with fillers.
Food containers, living hinges, consumer goods, automotive interiors.
Lightweight, chemical resistant, versatile.
HDPE (High-Density Polyethylene)
The Chemical & Moisture Barrier
20 - 30
40 - 200
Low strength and stiffness, poor temperature resistance.
Milk jugs, shampoo bottles, chemical tanks, food-safe packaging.
Excellent chemical resistance, moisture barrier, food-safe.
ABS (Acrylonitrile Butadiene Styrene)
The All-Rounder
40 - 50
200 - 400
Poor UV and weather resistance, low heat resistance.
Electronic housings, automotive trim, consumer product shells, LEGOs.
Best balance of strength, rigidity, impact, and surface finish.
ENGINEERING / PERFORMANCE POLYMERS
PC (Polycarbonate)
The Impact-Resistant Shield
55 - 75
600 - 850
Prone to scratching, susceptible to chemical stress cracking.
Safety glasses, bullet-resistant windows, transparent machine guards, electronic covers.
Exceptional impact strength, transparent, high heat resistance.
PC+ABS Blend
The Balanced Hybrid
45 - 55
300 - 500
Properties are a compromise; not as good as pure PC or ABS in their top traits.
Automotive dashboards, laptop housings, power tool bodies.
Perfect balance of PC's strength/heat and ABS's processability/finish.
PA (Nylon / Polyamide)
The Strong & Tough Workhorse
80 - 120*
40 - 150
Absorbs moisture, which affects dimensions and properties.
Gears, bearings, automotive under-hood parts, mechanical components.
High strength, stiffness, wear resistance, and heat resistance.
(with 30% GF)
POM (Acetal)
The Precision Engineer
60 - 70
60 - 120
Poor resistance to strong acids and bases.
Precision gears, conveyor belts, fasteners, zippers, fuel systems.
High stiffness, low friction, excellent fatigue resistance.
PCTG (Tritan™)
The Tough & Safe Transparent
50 - 55
700 - 900
Higher cost than PC or ABS.
Medical devices, baby bottles, small appliances, drinkware.
High clarity, excellent impact/chemical resistance, BPA-free.
FLEXIBLE / ELASTOMERIC POLYMERS
TPE (General)
The Soft & Squishy Gripper
20-Oct
N/A (Elongation: 300-600%)
Lower durability and chemical resistance than TPU/TPV.
Soft-grip handles, bottle stoppers, squeezable toys.
Soft, flexible, easy to process, cost-effective elastomer.
TPU (Thermoplastic Polyurethane)
The Abrasion-Resistant Tank
25 - 35
N/A (Elongation: 400-600%)
Can be susceptible to humidity during processing.
Phone cases, watch bands, athletic shoe soles, protective covers.
Extreme abrasion and tear resistance, tough, flexible.
TPV (Thermoplastic Vulcanizate)
The Weather-Resistant Seal
15-Oct
N/A (Elongation: 300-500%)
Softer, less rigid than TPU.
Automotive seals & gaskets, weather-stripping, outdoor hose coatings.
Excellent heat, weather, and UV resistance like traditional rubber.
SPECIALTY / SUSTAINABLE POLYMERS
PLA (Polylactic Acid)
The Sustainable Candidate
50 - 70*
15 - 30 (Brittle)
Very brittle, low heat resistance, degrades in humid environments.
Disposable cutlery, packaging, 3D printing filament (prototyping).
Biodegradable, bio-based, rigid.
(highly variable)
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