Materials / Compare
Aluminum 1100-O vs. Plastic Polycarbonate
Compare Aluminum 1100-O vs. Plastic Polycarbonate strength, stiffness, weight and thermal properties.
| Try it on a partA sample part to run stress or thermal on, free in your browser | Open in LessCAD | Open in LessCAD |
|---|---|---|
| Mechanical | ||
| Yield strength | 35MPasourcetypical, O, 0.0625 in specimen | 65MPasourcetypical, tensile yield |
| Ultimate tensile strength | 90MPasourcetypical, O | 65MPasourcetypical, stress at break |
| Flexural strength | not sourced | 97MPasourcetypical, flexural strength |
| Elongation at break | 35%sourcetypical, O, in 4D | 125%sourcetypical, strain at break |
| Young's modulus (stiffness) | 69GPasourcetypical28.8x stiffer | 2.4GPasourcetypical |
| Density | 2,710kg/m³sourcenominal, 20 °C | 1,200kg/m³sourcetypical |
| Strength to weight | 12.9kN·m/kg | 54.2kN·m/kg4.19x higher |
| Stiffness to weight | 25.5MN·m/kg12.7x higher | 2MN·m/kg |
| Poisson's ratio | not sourced | 0.38sourcetypical, polycarbonate family (Covestro Part and Mold Design guide, Table 3-1) |
| Shear modulus | not sourced | 0.87GPa |
| Bulk modulus | not sourced | 3.33GPa |
| Speed of sound | 5,046m/s | 1,414m/s |
| Thermal | ||
| Thermal conductivity | 222W/m·Ksourcetypical, O, 20 °C | 0.2W/m·Ksourcetypical, through-plane, 23 C |
| Thermal expansion | 23.6µm/m·Ksourcetypical, mean 20-100 °C | 65µm/m·Ksourcetypical, 23-55 C, parallel and normal |
| 100 mm part over a 50 °C swing | 118µm growth2.75x less | 325µm growth |
| Specific heat | 901J/kg·Ksourcebase material: commercially pure aluminium EN AW-1050A (Hydro), 20 °C | 1,172J/kg·Ksourcetypical (guide value), Bayer ASTM datasheet for Makrolon 2405, ASTM D 2766 |
| Heats up and cools (diffusivity) | 90.9mm²/s639x faster | 0.142mm²/s |
| Thermal shock resistance | not sourced | 51.7W/m |
| Melting point | 640–655°Csourcemelting range | not sourced |
| Glass transition | not sourced | 144°Csourcetypical, DSC 10 C/min |
| Max service temperature | not sourced | 125°CsourceUL 746B RTI, tensile strength, 1.5 mm |
| Values for | 1100-O (annealed) commercially pure aluminium, Kaiser Aluminum Tube & Pipe Alloy 1100 Technical Data (Rev. 05/06), typical properties; specific heat from Hydro EN AW-1050A (99.5% Al) extruded-products datasheet (10/2018). | Covestro Makrolon 2405 general-purpose PC (MVR 19), Covestro technical datasheet version 2026-09-28, typical values |
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.
Questions
Is Aluminum 1100-O stronger than Plastic Polycarbonate?
Plastic Polycarbonate is stronger: its yield strength is 65 MPa against 35 MPa for Aluminum 1100-O (1.86x).
Which is lighter, Aluminum 1100-O or Plastic Polycarbonate?
Plastic Polycarbonate is lighter: 1,200 kg/m³ against 2,710 kg/m³ for Aluminum 1100-O.
Which is stiffer, Aluminum 1100-O or Plastic Polycarbonate?
Aluminum 1100-O is stiffer: Young's modulus 69 GPa against 2.4 GPa for Plastic Polycarbonate, so the same part in Aluminum 1100-O deflects less under the same load.
Which is lighter for the same job, Aluminum 1100-O or Plastic Polycarbonate?
For the same stiffness or strength: Aluminum 1100-O is lighter for a stiff rod or tie (tension), stiff beam (bending), stiff panel or plate; Plastic Polycarbonate is lighter for a strong rod or tie, strong beam, strong panel or plate.
| Part that must be | Aluminum 1100-O | Plastic Polycarbonate |
|---|---|---|
| Stiff rod or tie (tension) | lighter | 12.7x heavier |
| Stiff beam (bending) | lighter | 2.37x heavier |
| Stiff panel or plate | lighter | 36% heavier |
| Strong rod or tie | 4.19x heavier | lighter |
| Strong beam | 3.41x heavier | lighter |
| Strong panel or plate | 3.08x 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 conducts heat better, Aluminum 1100-O or Plastic Polycarbonate?
Aluminum 1100-O conducts heat better: 222 W/m·K against 0.2 W/m·K for Plastic Polycarbonate.
Which expands less with temperature?
Aluminum 1100-O expands less: 23.6 µm/m·K against 65 µm/m·K for Plastic Polycarbonate.