6063-T6 extruded tube, Kaiser Aluminum Tube & Pipe Alloy 6063 Technical Data (Rev. 05/06), typical properties; specific heat from Hydro EN AW-6063 extruded-products datasheet (Rev.4, 03/2023).
Ultimaker ABS, 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 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.
Plastic ABS is 3D printed: its properties depend on build direction and print settings; these are typical values.
Questions
Is Aluminum 6063-T6 stronger than Plastic ABS?
Aluminum 6063-T6 is stronger: its yield strength is 215 MPa against 38.1 MPa for Plastic ABS (5.64x).
Which is lighter, Aluminum 6063-T6 or Plastic ABS?
Plastic ABS is lighter: 1,100 kg/m³ against 2,700 kg/m³ for Aluminum 6063-T6.
Which is stiffer, Aluminum 6063-T6 or Plastic ABS?
Aluminum 6063-T6 is stiffer: Young's modulus 69 GPa against 1.96 GPa for Plastic ABS, so the same part in Aluminum 6063-T6 deflects less under the same load.
Which is lighter for the same job, Aluminum 6063-T6 or Plastic ABS?
For the same stiffness or strength: Aluminum 6063-T6 is lighter for a stiff rod or tie (tension), stiff beam (bending), stiff panel or plate, strong rod or tie, strong beam; Plastic ABS is lighter for a strong panel or plate.
Part that must be
Aluminum 6063-T6
Plastic ABS
Stiff rod or tie (tension)
lighter
14.3x heavier
Stiff beam (bending)
lighter
2.42x heavier
Stiff panel or plate
lighter
33% heavier
Strong rod or tie
lighter
2.3x heavier
Strong beam
lighter
29% heavier
Strong panel or plate
3% 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 6063-T6 or Plastic ABS?
Aluminum 6063-T6 conducts heat better: 201 W/m·K against 0.17 W/m·K for Plastic ABS.
Which expands less with temperature?
Aluminum 6063-T6 expands less: 23.4 µm/m·K against 95 µm/m·K for Plastic ABS.