Materials / Compare
Aluminum vs. Plastic ABS
Compare Aluminum vs. Plastic ABS 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 | 38.1MPasourcetypical |
| Ultimate tensile strength | 310MPasourcetypical | 38.1MPasourcetypical, peak stress (= stress at yield) |
| Flexural strength | not sourced | 61.1MPasourcetypical |
| Elongation at break | 17%sourcetypical, in 4D, 0.500 in dia specimen | 4.6%sourcetypical |
| Young's modulus (stiffness) | 68.3GPasourcetypical34.8x stiffer | 1.96GPasourcetypical |
| Density | 2,700kg/m³sourcenominal | 1,100kg/m³sourcetypical |
| Strength to weight | 102kN·m/kg2.95x higher | 34.6kN·m/kg |
| Stiffness to weight | 25.3MN·m/kg14.2x higher | 1.78MN·m/kg |
| Poisson's ratio | 0.33sourcetypical (handbook physical constant) | 0.39sourcebase material: ABS family typical (Covestro Part and Mold Design guide, Table 3-1) |
| Shear modulus | 25.7GPa36.4x stiffer in shear | 0.706GPa |
| Bulk modulus | 67GPa | 2.97GPa |
| Speed of sound | 5,030m/s | 1,336m/s |
| Thermal | ||
| Thermal conductivity | 167W/m·Ksourcetypical, 20 °C | 0.17W/m·Ksourcebase material: INEOS Styrolution Terluran GP-22 injection-molding ABS, typical |
| Thermal expansion | 23.6µm/m·Ksourcetypical, mean 20-100 °C | 80–110µm/m·Ksourcebase material: INEOS Styrolution Terluran GP-22 injection-molding ABS, range |
| 100 mm part over a 50 °C swing | 118µm growth4.03x less | 475µm 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/m904x more resistant | 21.2W/m |
| Melting point | 582–652°Csourcesolidus-liquidus | not sourced |
| Glass transition | not sourced | 101°Csourcetypical |
| Max service temperature | not sourced | 86.6°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 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 stronger than Plastic ABS?
Aluminum is stronger: its yield strength is 276 MPa against 38.1 MPa for Plastic ABS (7.24x).
Which is lighter, Aluminum or Plastic ABS?
Plastic ABS is lighter: 1,100 kg/m³ against 2,700 kg/m³ for Aluminum.
Which is stiffer, Aluminum or Plastic ABS?
Aluminum is stiffer: Young's modulus 68.3 GPa against 1.96 GPa for Plastic ABS, so the same part in Aluminum deflects less under the same load.
Which is lighter for the same job, Aluminum or Plastic ABS?
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, strong panel or plate.
| Part that must be | Aluminum | Plastic ABS |
|---|---|---|
| Stiff rod or tie (tension) | lighter | 14.2x heavier |
| Stiff beam (bending) | lighter | 2.4x heavier |
| Stiff panel or plate | lighter | 33% heavier |
| Strong rod or tie | lighter | 2.95x heavier |
| Strong beam | lighter | 1.53x heavier |
| Strong panel or plate | lighter | 10% heavier |
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 Plastic ABS?
Aluminum conducts heat better: 167 W/m·K against 0.17 W/m·K for Plastic ABS.
Which expands less with temperature?
Aluminum expands less: 23.6 µm/m·K against 95 µm/m·K for Plastic ABS.