Aluminum 5052-H32 vs. FDM Polycarbonate

Compare Aluminum 5052-H32 vs. FDM Polycarbonate strength, stiffness, weight and thermal properties.

Change either side

Mechanical
Try it on a partA bracket to run stress or thermal on, free in your browser	Open in LessCAD	Open in LessCAD
Yield strength	195MPasourcetypical, 0.2% offset	53.3MPasourcetypical
Ultimate tensile strength	230MPasourcetypical	53.3MPasourcetypical, peak stress (= stress at yield)
Flexural strength	not sourced	89.4MPasourcetypical
Elongation at break	12%sourcetypical30% more ductile	9.2%sourcetypical
Young's modulus (stiffness)	70GPasourcetypical29.2x stiffer	2.39GPasourcetypical
Density	2,685kg/m³sourcenominal	1,180–1,200kg/m³sourcerange
Strength to weight	72.6kN·m/kg1.62x higher	44.8kN·m/kg
Stiffness to weight	26.1MN·m/kg13x higher	2.01MN·m/kg
Poisson's ratio	0.33sourcetypical (handbook physical constant)	0.38sourcebase material: polycarbonate family typical (Covestro Part and Mold Design guide, Table 3-1)
Shear modulus	26.3GPa30.3x stiffer in shear	0.867GPa
Bulk modulus	68.6GPa	3.33GPa
Speed of sound	5,106m/s	1,418m/s
Thermal
Thermal conductivity	138W/m·Ksourcebase material: 5052 in O temper (same alloy, annealed); Kaiser typical	0.2W/m·Ksourcebase material: Covestro Makrolon 2405 injection-molding PC, typical, through-plane, 23 °C
Thermal expansion	23.8µm/m·Ksourcetypical, mean 20-100 °C	65µm/m·Ksourcebase material: Covestro Makrolon 2405 injection-molding PC, typical, 23-55 °C, parallel
100 mm part over a 50 °C swing	119µm growth2.73x less	325µm growth
Specific heat	963J/kg·Ksourceat 100 °C (212 °F); table covers O, H32, H34, H36, H38	not sourced
Heats up and cools (diffusivity)	53.4mm²/s	not sourced
Thermal shock resistance	10,822W/m255x more resistant	42.5W/m
Melting point	605–650°Csourcemelting range	not sourced
Glass transition	not sourced	108°Csourcetypical
Max service temperature	not sourced	105°CsourceHDT 0.455 MPa (printed specimens)
Values for	5052-H32, Kaiser Aluminum tube & pipe typical datasheet (mechanical, CTE, melting); MIL-HDBK-5J (Poisson, density, specific heat)	Ultimaker 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 5052-H32 stronger than FDM Polycarbonate?

Aluminum 5052-H32 is stronger: its yield strength is 195 MPa against 53.3 MPa for FDM Polycarbonate (3.66x).

Which is lighter, Aluminum 5052-H32 or FDM Polycarbonate?

FDM Polycarbonate is lighter: 1,190 kg/m³ against 2,685 kg/m³ for Aluminum 5052-H32.

Which is stiffer, Aluminum 5052-H32 or FDM Polycarbonate?

Aluminum 5052-H32 is stiffer: Young's modulus 70 GPa against 2.39 GPa for FDM Polycarbonate, so the same part in Aluminum 5052-H32 deflects less under the same load.

Which is lighter for the same job, Aluminum 5052-H32 or FDM Polycarbonate?

For the same stiffness or strength: Aluminum 5052-H32 is lighter for a stiff rod or tie (tension), stiff beam (bending), stiff panel or plate, strong rod or tie, strong beam; FDM Polycarbonate is lighter for a strong panel or plate.

Part that must be	Aluminum 5052-H32	FDM Polycarbonate
Stiff rod or tie (tension)	lighter	13x heavier
Stiff beam (bending)	lighter	2.4x heavier
Stiff panel or plate	lighter	37% heavier
Strong rod or tie	lighter	1.62x heavier
Strong beam	lighter	5% heavier
Strong panel or plate	18% heavier	lighter

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 is more ductile, Aluminum 5052-H32 or FDM Polycarbonate?

Aluminum 5052-H32 stretches further before it breaks: 12% elongation at break against 9.2% for FDM Polycarbonate.

Which conducts heat better, Aluminum 5052-H32 or FDM Polycarbonate?

Aluminum 5052-H32 conducts heat better: 138 W/m·K against 0.2 W/m·K for FDM Polycarbonate.

Which expands less with temperature?

Aluminum 5052-H32 expands less: 23.8 µm/m·K against 65 µm/m·K for FDM Polycarbonate.

Among 59 materials

Stiffness against density

Strength against density