Thermal conductivity against densityHigher and further left: spreads more heat for its weightThermal expansion against thermal conductivityLower and further right: warps less when heated
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Sources4 documents: Kaiser Aluminum, UltiMaker, Covestro
Aluminum 3003-O
3003-O (annealed) aluminium-manganese alloy, the heat-exchanger tube and brazing alloy, Kaiser Aluminum Tube & Pipe Alloy 3003 Technical Data (Rev. 05/06), typical properties; specific heat from the NIST cryogenic 3003-F fit at 293 K.
FDM Polycarbonate
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.
1
Alloy 3003 Tube & Pipe Technical Data, Rev. 05/06Kaiser Aluminumarchived copyAluminum 3003-O · Yield strength: typical, O, 0.0625 in specimenAluminum 3003-O · Ultimate tensile strength: typical, OAluminum 3003-O · Elongation at break: typical, O, in 4DAluminum 3003-O · Young's modulus (stiffness): typicalAluminum 3003-O · Density: nominal, 20 °CAluminum 3003-O · Thermal conductivity: typical, O, 20 °CAluminum 3003-O · Thermal expansion: typical, mean 20-100 °CAluminum 3003-O · Melting point: melting range
2
Ultimaker PC Technical Data Sheet, v5.00UltiMakerarchived copyFDM Polycarbonate · Yield strength: typicalFDM Polycarbonate · Ultimate tensile strength: typical, peak stress (= stress at yield)FDM Polycarbonate · Flexural strength: typicalFDM Polycarbonate · Elongation at break: typicalFDM Polycarbonate · Young's modulus (stiffness): typicalFDM Polycarbonate · Density: rangeFDM Polycarbonate · Glass transition: typicalFDM Polycarbonate · Max service temperature: HDT 0.455 MPa (printed specimens)
3
Engineering Polymers Part and Mold Design: Thermoplastics, A Design GuideCovestroarchived copyFDM Polycarbonate · Poisson's ratio: base material: polycarbonate family typical (Covestro Part and Mold Design guide, Table 3-1)
4
Makrolon 2405 Technical Data SheetCovestroFDM Polycarbonate · Thermal conductivity: base material: Covestro Makrolon 2405 injection-molding PC, typical, through-plane, 23 °CFDM Polycarbonate · Thermal expansion: base material: Covestro Makrolon 2405 injection-molding PC, typical, 23-55 °C, parallel
Each number points to the document that states it, with the exact basis. Values without a number are computed from the sourced ones. "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
Mechanical
Is Aluminum 3003-O stronger than FDM Polycarbonate?
FDM Polycarbonate is stronger: its yield strength is 53.3 MPa against 40 MPa for Aluminum 3003-O (33%).
Which is lighter, Aluminum 3003-O or FDM Polycarbonate?
FDM Polycarbonate is lighter: 1,190 kg/m³ against 2,730 kg/m³ for Aluminum 3003-O.
Which is stiffer, Aluminum 3003-O or FDM Polycarbonate?
Aluminum 3003-O is stiffer: Young's modulus 69 GPa against 2.39 GPa for FDM Polycarbonate, so the same part in Aluminum 3003-O deflects less under the same load.
Which is lighter for the same job, Aluminum 3003-O or FDM Polycarbonate?
For the same stiffness or strength: Aluminum 3003-O is lighter for a stiff rod or tie (tension), stiff beam (bending), stiff panel or plate; FDM Polycarbonate is lighter for a strong rod or tie, strong beam, strong panel or plate.
Part that must be
Aluminum 3003-O
FDM Polycarbonate
Stiff rod or tie (tension)
lighter
12.6x heavier
Stiff beam (bending)
lighter
2.34x heavier
Stiff panel or plate
lighter
34% heavier
Strong rod or tie
3.06x heavier
lighter
Strong beam
2.78x heavier
lighter
Strong panel or plate
2.65x 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 3003-O or FDM Polycarbonate?
Aluminum 3003-O stretches further before it breaks: 30% elongation at break against 9.2% for FDM Polycarbonate.
Thermal
Which conducts heat better, Aluminum 3003-O or FDM Polycarbonate?
Aluminum 3003-O conducts heat better: 193 W/m·K against 0.2 W/m·K for FDM Polycarbonate.
Which expands less with temperature?
Aluminum 3003-O expands less: 23.2 µm/m·K against 65 µm/m·K for FDM Polycarbonate.