Plastic ABS (bulk/injection) vs. DMLS AlSi10Mg Aluminum

Compare Plastic ABS (bulk/injection) vs. DMLS AlSi10Mg Aluminum strength, stiffness, weight and thermal properties.

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Plastic ABS (bulk/injection)Bulk polymer (molded or machined)

DMLS AlSi10Mg Aluminum3D printed metal (DMLS)

Mechanical
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Yield strength	45MPasourcetypical, tensile stress at yield 23 °C	270MPasourcetypical, as manufactured, horizontal
Ultimate tensile strength	not sourced	450MPasourcetypical, as manufactured, horizontal
Flexural strength	65MPasourcetypical, 23 °C	not sourced
Elongation at break	10%sourcenominal strain at break, 23 °C	10.2%sourcetypical at break, as manufactured, horizontal
Young's modulus (stiffness)	2.3GPasourcetypical	72GPasourcesame material and process, different machine maker: Renishaw RenAM 500, 30 µm, as built, horizontal (XY)
Density	1,040kg/m³sourcetypical	2,670kg/m³sourcetypical part density (ISO 3369), EOS M 290, AlSi10Mg_030_FlexM291 (30 µm)
Strength to weight	43.3kN·m/kg	101kN·m/kg2.34x higher
Stiffness to weight	2.21MN·m/kg	27MN·m/kg12.2x higher
Poisson's ratio	0.39sourcetypical, ABS family (Covestro Part and Mold Design guide, Table 3-1)	0.33sourcebase material: cast Al-Si-Mg alloy 359.0 (Al-9Si-0.6Mg, closest MIL-HDBK-5J alloy to AlSi10Mg / EN AC-43000)
Shear modulus	0.827GPa	27.1GPa32.7x stiffer in shear
Bulk modulus	3.48GPa	70.6GPa
Speed of sound	1,487m/s	5,193m/s
Thermal
Thermal conductivity	0.17W/m·Ksourcetypical	110W/m·Ksourcetypical, as manufactured, horizontal (ISO 22007-2)
Thermal expansion	80–110µm/m·Ksourcerange	20µm/m·Ksourcemean 25-100 °C, ASTM E228
100 mm part over a 50 °C swing	475µm growth	100µm growth4.75x less
Specific heat	not sourced	963J/kg·Ksourcebase material: cast Al-Si-Mg alloy 359.0 (MIL-HDBK-5J), at 100 °C
Heats up and cools (diffusivity)	not sourced	42.8mm²/s
Thermal shock resistance	21.4W/m	13,819W/m647x more resistant
Max service temperature	94°CsourceHDT 1.8 MPa (annealed 4 h/80 °C)	not sourced
Values for	INEOS Styrolution Terluran GP-22 general-purpose injection-molding ABS, ISO typical values (TDS revision 08/01/2022)	EOS Aluminium AlSi10Mg (powder 9011-0024), EOS M 290 \| 30 µm process (AlSi10Mg_FlexM291 2.01), as manufactured, horizontal; machined (turned) specimens, ISO 6892-1 B10

Every value links to the document that states it. "Not sourced" means no citable source states it (or only a specification minimum); figures computed from it are left out too.

DMLS AlSi10Mg Aluminum is 3D printed: its properties depend on build direction and print settings; these are typical values.

Questions

Is Plastic ABS (bulk/injection) stronger than DMLS AlSi10Mg Aluminum?

DMLS AlSi10Mg Aluminum is stronger: its yield strength is 270 MPa against 45 MPa for Plastic ABS (bulk/injection) (6x).

Which is lighter, Plastic ABS (bulk/injection) or DMLS AlSi10Mg Aluminum?

Plastic ABS (bulk/injection) is lighter: 1,040 kg/m³ against 2,670 kg/m³ for DMLS AlSi10Mg Aluminum.

Which is stiffer, Plastic ABS (bulk/injection) or DMLS AlSi10Mg Aluminum?

DMLS AlSi10Mg Aluminum is stiffer: Young's modulus 72 GPa against 2.3 GPa for Plastic ABS (bulk/injection), so the same part in DMLS AlSi10Mg Aluminum deflects less under the same load.

Which is lighter for the same job, Plastic ABS (bulk/injection) or DMLS AlSi10Mg Aluminum?

For the same stiffness or strength: Plastic ABS (bulk/injection) is lighter for a strong panel or plate; DMLS AlSi10Mg Aluminum is lighter for a stiff rod or tie (tension), stiff beam (bending), stiff panel or plate, strong rod or tie, strong beam.

Part that must be	Plastic ABS (bulk/injection)	DMLS AlSi10Mg Aluminum
Stiff rod or tie (tension)	12.2x heavier	lighter
Stiff beam (bending)	2.18x heavier	lighter
Stiff panel or plate	23% heavier	lighter
Strong rod or tie	2.34x heavier	lighter
Strong beam	29% heavier	lighter
Strong panel or plate	lighter	5% heavier

For the same stiffness or strength, mass scales with density over stiffness (or strength) raised to a power set by how the part is loaded: 1 for a rod in tension, 1/2 for a beam in bending, 1/3 for a panel (the standard material-selection indices).

Which conducts heat better, Plastic ABS (bulk/injection) or DMLS AlSi10Mg Aluminum?

DMLS AlSi10Mg Aluminum conducts heat better: 110 W/m·K against 0.17 W/m·K for Plastic ABS (bulk/injection).

Which expands less with temperature?

DMLS AlSi10Mg Aluminum expands less: 20 µm/m·K against 95 µm/m·K for Plastic ABS (bulk/injection).

Among 59 materials

Stiffness against density

Strength against density