Materials / Compare
Aluminum vs. FDM Polycarbonate
Compare Aluminum vs. FDM Polycarbonate strength, stiffness, weight and thermal properties.
| Try it on a partA bracket to run stress or thermal on, free in your browser | Open in LessCAD | Open in LessCAD |
|---|---|---|
| Mechanical | ||
| Yield strength | 276MPasourcetypical, 0.2% offset, .500 in dia specimen | 53.3MPasourcetypical |
| Ultimate tensile strength | 310MPasourcetypical | 53.3MPasourcetypical, peak stress (= stress at yield) |
| Flexural strength | not sourced | 89.4MPasourcetypical |
| Elongation at break | 17%sourcetypical, in 4D, 0.500 in dia specimen | 9.2%sourcetypical |
| Young's modulus (stiffness) | 68.3GPasourcetypical28.5x stiffer | 2.39GPasourcetypical |
| Density | 2,700kg/m³sourcenominal | 1,180–1,200kg/m³sourcerange |
| Strength to weight | 102kN·m/kg2.28x higher | 44.8kN·m/kg |
| Stiffness to weight | 25.3MN·m/kg12.6x 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 | 25.7GPa29.6x stiffer in shear | 0.867GPa |
| Bulk modulus | 67GPa | 3.33GPa |
| Speed of sound | 5,030m/s | 1,418m/s |
| Thermal | ||
| Thermal conductivity | 167W/m·Ksourcetypical, 20 °C | 0.2W/m·Ksourcebase material: Covestro Makrolon 2405 injection-molding PC, typical, through-plane, 23 °C |
| Thermal expansion | 23.6µm/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 | 118µm growth2.75x less | 325µm growth |
| Specific heat | 896J/kg·Ksourcetypical, at 100 °C | not sourced |
| Heats up and cools (diffusivity) | 69mm²/s | not sourced |
| Thermal shock resistance | 19,159W/m451x more resistant | 42.5W/m |
| Melting point | 582–652°Csourcesolidus-liquidus | not sourced |
| Glass transition | not sourced | 108°Csourcetypical |
| Max service temperature | not sourced | 105°CsourceHDT 0.455 MPa (printed specimens) |
| Values for | 6061-T6/T651, Kaiser Aluminum typical properties (sheet, coil & plate datasheet); Poisson from MIL-HDBK-5J | 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 stronger than FDM Polycarbonate?
Aluminum is stronger: its yield strength is 276 MPa against 53.3 MPa for FDM Polycarbonate (5.18x).
Which is lighter, Aluminum or FDM Polycarbonate?
FDM Polycarbonate is lighter: 1,190 kg/m³ against 2,700 kg/m³ for Aluminum.
Which is stiffer, Aluminum or FDM Polycarbonate?
Aluminum is stiffer: Young's modulus 68.3 GPa against 2.39 GPa for FDM Polycarbonate, so the same part in Aluminum deflects less under the same load.
Which is lighter for the same job, Aluminum or FDM Polycarbonate?
For the same stiffness or strength: 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 | Aluminum | FDM Polycarbonate |
|---|---|---|
| Stiff rod or tie (tension) | lighter | 12.6x heavier |
| Stiff beam (bending) | lighter | 2.35x heavier |
| Stiff panel or plate | lighter | 35% heavier |
| Strong rod or tie | lighter | 2.28x heavier |
| Strong beam | lighter | 32% 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, Aluminum or FDM Polycarbonate?
Aluminum conducts heat better: 167 W/m·K against 0.2 W/m·K for FDM Polycarbonate.
Which expands less with temperature?
Aluminum expands less: 23.6 µm/m·K against 65 µm/m·K for FDM Polycarbonate.