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Aluminum 2024-T351 vs. FDM Polycarbonate

Compare Aluminum 2024-T351 vs. FDM Polycarbonate strength, stiffness, weight and thermal properties.

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Aluminum 2024-T351Wrought
FDM Polycarbonate3D printed (FDM)
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Mechanical
Yield strength324MPasourcetypical, 0.2% offset, .500 in dia specimen53.3MPasourcetypical
Ultimate tensile strength469MPasourcetypical53.3MPasourcetypical, peak stress (= stress at yield)
Flexural strengthnot sourced89.4MPasourcetypical
Elongation at break19%sourcetypical, in 4D9.2%sourcetypical
Young's modulus (stiffness)73.1GPasourcetypical30.5x stiffer2.39GPasourcetypical
Density2,770kg/m³sourcenominal1,180–1,200kg/m³sourcerange
Strength to weight117kN·m/kg2.61x higher44.8kN·m/kg
Stiffness to weight26.4MN·m/kg13.1x higher2.01MN·m/kg
Poisson's ratio0.33sourcetypical (handbook physical constant), all tempers0.38sourcebase material: polycarbonate family typical (Covestro Part and Mold Design guide, Table 3-1)
Shear modulus27.5GPa31.7x stiffer in shear0.867GPa
Bulk modulus71.7GPa3.33GPa
Speed of sound5,137m/s1,418m/s
Thermal
Thermal conductivity120W/m·Ksourcetypical, 20 °C0.2W/m·Ksourcebase material: Covestro Makrolon 2405 injection-molding PC, typical, through-plane, 23 °C
Thermal expansion22.9µm/m·Ksourcetypical, mean 20-100 °C65µm/m·Ksourcebase material: Covestro Makrolon 2405 injection-molding PC, typical, 23-55 °C, parallel
100 mm part over a 50 °C swing115µm growth2.84x less325µm growth
Specific heat875J/kg·Ksourcetypical, at 100 °Cnot sourced
Heats up and cools (diffusivity)49.5mm²/snot sourced
Thermal shock resistance15,561W/m366x more resistant42.5W/m
Melting point502–638°Csourcemelting rangenot sourced
Glass transitionnot sourced108°Csourcetypical
Max service temperaturenot sourced105°CsourceHDT 0.455 MPa (printed specimens)
Values for2024-T4/T351, Kaiser Aluminum sheet, coil & plate typical datasheet; Poisson from MIL-HDBK-5JUltimaker PC, 3D-printed specimens, XY (flat); Ultimaker S5 Pro, engineering intent profile, 0.15 mm layer height, AA 0.4 print core, 100% infill, Cura 4.9, printed one-at-a-time, conditioned >=24 h at room temperature. TDS (file v5.00), April 20, 2022.

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.

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

Questions

Is Aluminum 2024-T351 stronger than FDM Polycarbonate?

Aluminum 2024-T351 is stronger: its yield strength is 324 MPa against 53.3 MPa for FDM Polycarbonate (6.08x).

Which is lighter, Aluminum 2024-T351 or FDM Polycarbonate?

FDM Polycarbonate is lighter: 1,190 kg/m³ against 2,770 kg/m³ for Aluminum 2024-T351.

Which is stiffer, Aluminum 2024-T351 or FDM Polycarbonate?

Aluminum 2024-T351 is stiffer: Young's modulus 73.1 GPa against 2.39 GPa for FDM Polycarbonate, so the same part in Aluminum 2024-T351 deflects less under the same load.

Which is lighter for the same job, Aluminum 2024-T351 or FDM Polycarbonate?

For the same stiffness or strength: Aluminum 2024-T351 is lighter for a stiff rod or tie (tension), stiff beam (bending), stiff panel or plate, strong rod or tie, strong beam, strong panel or plate.

Part that must beAluminum 2024-T351FDM Polycarbonate
Stiff rod or tie (tension)lighter13.1x heavier
Stiff beam (bending)lighter2.37x heavier
Stiff panel or platelighter34% heavier
Strong rod or tielighter2.61x heavier
Strong beamlighter43% heavier
Strong panel or platelighter6% 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, Aluminum 2024-T351 or FDM Polycarbonate?

Aluminum 2024-T351 conducts heat better: 120 W/m·K against 0.2 W/m·K for FDM Polycarbonate.

Which expands less with temperature?

Aluminum 2024-T351 expands less: 22.9 µm/m·K against 65 µm/m·K for FDM Polycarbonate.

Among 59 materials

1k10k0.1110100Density (kg/m³)Young's modulus (GPa)Plastic PLAPlastic PETGPlastic ABSPlastic TPUPlastic NylonAluminumSteelIronTitaniumSteel AISI 1018Stainless 304Stainless 316Aluminum 6061-T6Aluminum 7075-T6Brass C360Copper C110GlassSteel AISI 1045Steel AISI 4340Steel A992Stainless 303Stainless 17-4PHAluminum 5052-H32Aluminum 7050-T7451Titanium Ti-6Al-4VBrass C260Nickel Inconel 718Magnesium AZ31B-H24Zinc Zamak 3Plastic ABS (bulk/injection)Plastic PolycarbonatePlastic POM/AcetalPlastic Nylon PA6Plastic Nylon PA66Plastic PEEKPlastic UHMWPEPlastic HDPEPlastic PolypropylenePlastic PMMAFDM ASAFDM PAHT-CFFDM HIPSSLA Resin Tough 2000SLS PA12 NylonDMLS AlSi10Mg AluminumDMLS Ti-6Al-4V ELI TitaniumDMLS 316L Stainless SteelDMLS 17-4PH Stainless SteelAluminum 2024-T351FDM Polycarbonate
Stiffness against density
1k10k101001kDensity (kg/m³)Yield strength (MPa)Plastic PLAPlastic PETGPlastic ABSPlastic TPUPlastic NylonRubberAluminumSteelIronTitaniumSteel AISI 1018Stainless 304Stainless 316Aluminum 6061-T6Aluminum 7075-T6Brass C360Copper C110GlassSteel AISI 1045Steel AISI 4340Steel A992Stainless 303Stainless 17-4PHAluminum 5052-H32Aluminum 7050-T7451Titanium Ti-6Al-4VBrass C260Nickel Inconel 718Magnesium AZ31B-H24Zinc Zamak 3Plastic ABS (bulk/injection)Plastic PolycarbonatePlastic POM/AcetalPlastic Nylon PA6Plastic Nylon PA66Plastic PEEKPlastic PTFEPlastic UHMWPEPlastic HDPEPlastic PolypropylenePlastic PMMAFDM ASAFDM PAHT-CFFDM HIPSSLA Resin Tough 2000SLA Resin Elastic 50ASLS PA12 NylonDMLS AlSi10Mg AluminumDMLS Ti-6Al-4V ELI TitaniumDMLS 316L Stainless SteelDMLS 17-4PH Stainless SteelBrickAluminum 2024-T351FDM Polycarbonate
Strength against density

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