DMLS AlSi10Mg Aluminum vs. FDM Polycarbonate

Compare DMLS AlSi10Mg Aluminum vs. FDM Polycarbonate strength, stiffness, weight and thermal properties.

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DMLS AlSi10Mg Aluminum3D printed metal (DMLS)

Mechanical
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Yield strength	270MPasourcetypical, as manufactured, horizontal	53.3MPasourcetypical
Ultimate tensile strength	450MPasourcetypical, as manufactured, horizontal	53.3MPasourcetypical, peak stress (= stress at yield)
Flexural strength	not sourced	89.4MPasourcetypical
Elongation at break	10.2%sourcetypical at break, as manufactured, horizontal	9.2%sourcetypical
Young's modulus (stiffness)	72GPasourcesame material and process, different machine maker: Renishaw RenAM 500, 30 µm, as built, horizontal (XY)	2.39GPasourcetypical
Density	2,670kg/m³sourcetypical part density (ISO 3369), EOS M 290, AlSi10Mg_030_FlexM291 (30 µm)	1,180–1,200kg/m³sourcerange
Strength to weight	101kN·m/kg2.26x higher	44.8kN·m/kg
Stiffness to weight	27MN·m/kg13.4x higher	2.01MN·m/kg
Poisson's ratio	0.33sourcebase material: cast Al-Si-Mg alloy 359.0 (Al-9Si-0.6Mg, closest MIL-HDBK-5J alloy to AlSi10Mg / EN AC-43000)	0.38sourcebase material: polycarbonate family typical (Covestro Part and Mold Design guide, Table 3-1)
Shear modulus	27.1GPa31.2x stiffer in shear	0.867GPa
Bulk modulus	70.6GPa	3.33GPa
Speed of sound	5,193m/s	1,418m/s
Thermal
Thermal conductivity	110W/m·Ksourcetypical, as manufactured, horizontal (ISO 22007-2)	0.2W/m·Ksourcebase material: Covestro Makrolon 2405 injection-molding PC, typical, through-plane, 23 °C
Thermal expansion	20µm/m·Ksourcemean 25-100 °C, ASTM E228	65µm/m·Ksourcebase material: Covestro Makrolon 2405 injection-molding PC, typical, 23-55 °C, parallel
100 mm part over a 50 °C swing	100µm growth3.25x less	325µm growth
Specific heat	963J/kg·Ksourcebase material: cast Al-Si-Mg alloy 359.0 (MIL-HDBK-5J), at 100 °C	not sourced
Heats up and cools (diffusivity)	42.8mm²/s	not sourced
Thermal shock resistance	13,819W/m325x more resistant	42.5W/m
Glass transition	not sourced	108°Csourcetypical
Max service temperature	not sourced	105°CsourceHDT 0.455 MPa (printed specimens)
Values for	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	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.

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

Questions

Is DMLS AlSi10Mg Aluminum stronger than FDM Polycarbonate?

DMLS AlSi10Mg Aluminum is stronger: its yield strength is 270 MPa against 53.3 MPa for FDM Polycarbonate (5.07x).

Which is lighter, DMLS AlSi10Mg Aluminum or FDM Polycarbonate?

FDM Polycarbonate is lighter: 1,190 kg/m³ against 2,670 kg/m³ for DMLS AlSi10Mg Aluminum.

Which is stiffer, DMLS AlSi10Mg Aluminum or FDM Polycarbonate?

DMLS AlSi10Mg Aluminum is stiffer: Young's modulus 72 GPa against 2.39 GPa for FDM Polycarbonate, so the same part in DMLS AlSi10Mg Aluminum deflects less under the same load.

Which is lighter for the same job, DMLS AlSi10Mg Aluminum or FDM Polycarbonate?

For the same stiffness or strength: 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	DMLS AlSi10Mg Aluminum	FDM Polycarbonate
Stiff rod or tie (tension)	lighter	13.4x heavier
Stiff beam (bending)	lighter	2.44x heavier
Stiff panel or plate	lighter	39% heavier
Strong rod or tie	lighter	2.26x heavier
Strong beam	lighter	31% heavier
Strong panel or plate	about equal	about equal

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, DMLS AlSi10Mg Aluminum or FDM Polycarbonate?

DMLS AlSi10Mg Aluminum conducts heat better: 110 W/m·K against 0.2 W/m·K for FDM Polycarbonate.

Which expands less with temperature?

DMLS AlSi10Mg Aluminum expands less: 20 µm/m·K against 65 µm/m·K for FDM Polycarbonate.

Among 59 materials

Stiffness against density

Strength against density