Compare material properties, pricing, and manufacturing considerations
ABS Prototypes
Acrylonitrile Butadiene Styrene (ABS) is a popular thermoplastic polymer widely used in plastic prototype manufacturing due to its excellent impact resistance and machinability. This engineering plastic maintains good dimensional stability and can be easily processed using both CNC machining and 3D printing technologies. ABS prototypes are ideal for functional testing, automotive components, and consumer electronics enclosures.
Polyoxymethylene (POM), commonly known as Acetal, is a high-precision engineering plastic offering exceptional dimensional stability and low friction coefficient. Its excellent wear resistance makes it perfect for manufacturing prototypes of gears, bearings, and other mechanical components. POM prototypes maintain tight tolerances (±0.05mm) and perform well in moist environments.
Key Advantages
Low moisture absorption
Excellent creep resistance
FDA compliant
Technical Specifications
Tensile Strength
70 MPa
Temperature Range
-50°C to 100°C
Density
1.41-1.42 g/cm³
Price Range
$0.8-$1.2/cm³
Typical Applications
Precision gearsMedical devicesFood handling systems
PC (Polycarbonate) Prototypes
Polycarbonate (PC) is renowned for its exceptional impact strength and optical clarity, making it ideal for transparent prototypes and protective components. With a heat deflection temperature of 135°C, PC prototypes can withstand demanding environments while maintaining dimensional accuracy. This material is particularly suitable for LED lighting components and safety equipment prototypes.
Nylon (Polyamide) offers superior wear resistance and fatigue endurance, making it perfect for functional prototypes requiring repeated mechanical stress. With excellent chemical resistance and low friction coefficient, PA prototypes are widely used in automotive and industrial applications. Available in various grades including PA6, PA66, and glass-filled variants.
Key Advantages
High fatigue resistance
Good chemical stability
Low friction
Technical Specifications
Tensile Strength
85 MPa
Temperature Range
-40°C to 120°C
Density
1.13-1.15 g/cm³
Price Range
$0.7-$1.0/cm³
Typical Applications
Wear padsBushingsConveyor components
PMMA (Acrylic) Prototypes
Acrylic (PMMA) provides exceptional optical clarity (92% light transmission) and weather resistance, serving as an ideal alternative to glass for transparent prototypes. PMMA prototypes can be polished to optical-grade surfaces and are widely used in lighting systems, display prototypes, and architectural models. Offers better scratch resistance than standard polycarbonate.
Key Advantages
Optical clarity
Weather resistance
Easy polishing
Technical Specifications
Tensile Strength
70 MPa
Temperature Range
-40°C to 90°C
Density
1.17-1.20 g/cm³
Price Range
$0.6-$0.9/cm³
Typical Applications
Light guidesDisplay modelsSignage prototypes
PEEK Prototypes
Polyether Ether Ketone (PEEK) is a high-performance thermoplastic for extreme environment prototypes. With continuous service temperature up to 260°C and exceptional chemical resistance, PEEK prototypes are essential for aerospace, oil/gas, and medical applications. Offers excellent mechanical properties retention at elevated temperatures.
Key Advantages
Flame retardant
Sterilizable
High purity
Technical Specifications
Tensile Strength
100 MPa
Temperature Range
-100°C to 260°C
Density
1.32 g/cm³
Price Range
$8-$12/cm³
Typical Applications
Downhole toolsSurgical instrumentsSemiconductor parts
PP (Polypropylene) Prototypes
Polypropylene (PP) is a lightweight, chemical-resistant material ideal for living hinge prototypes and corrosion-resistant components. With excellent fatigue resistance and FDA compliance, PP prototypes are widely used in packaging, fluid handling, and medical applications. Offers good impact strength at low temperatures.
Key Advantages
Excellent chemical resistance
Low density
Fatigue resistance
Technical Specifications
Tensile Strength
35 MPa
Temperature Range
-20°C to 120°C
Density
0.90-0.91 g/cm³
Price Range
$0.4-$0.6/cm³
Typical Applications
Living hingesChemical tanksMedical trays
PE (Polyethylene) Prototypes
Polyethylene (PE) offers excellent moisture resistance and electrical insulation properties, making it suitable for prototypes in harsh environments. Available in HDPE and UHMW grades, PE prototypes are used in material handling, packaging, and industrial applications. Features low coefficient of friction and good impact resistance.
Key Advantages
Moisture resistant
Electrical insulation
Low cost
Technical Specifications
Tensile Strength
25 MPa
Temperature Range
-50°C to 80°C
Density
0.93-0.97 g/cm³
Price Range
$0.3-$0.5/cm³
Typical Applications
Wear stripsFood packagingChemical containers
Plastic Material Comparison Chart
Material
Tensile (MPa)
Max Temp
Price Range
Machinability
ABS
40 MPa
80°C
$0.5-$0.8/cm³
POM (Acetal)
70 MPa
100°C
$0.8-$1.2/cm³
PC (Polycarbonate)
65 MPa
135°C
$1.0-$1.5/cm³
PA (Nylon)
85 MPa
120°C
$0.7-$1.0/cm³
PMMA (Acrylic)
70 MPa
90°C
$0.6-$0.9/cm³
PEEK
100 MPa
260°C
$8-$12/cm³
PP (Polypropylene)
35 MPa
120°C
$0.4-$0.6/cm³
PE (Polyethylene)
25 MPa
80°C
$0.3-$0.5/cm³
* Prices based on standard CNC machining of 100cm³ volume
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Precision Plastic Prototype Manufacturing Process
1
Design & Engineering Analysis
CAD File Optimization
DFM analysis using Siemens NX for CNC/3D printing compatibility, checking wall thickness (min. 1.2mm), draft angles (≥2°), and undercut feasibility
Material Selection Matrix
Technical evaluation based on: - Thermal requirements (HDT @ 0.45MPa/1.82MPa) - Chemical exposure (ASTM D543 testing) - Regulatory compliance (ISO 10993, UL94)
2
Manufacturing Execution
CNC Machining Parameters
Material
Speed (m/min)
Feed (mm/tooth)
Tool Type
ABS
200-300
0.08-0.12
2-flute carbide
PEEK
120-180
0.05-0.08
Diamond-coated
Additive Manufacturing
SLS Nylon: 100μm layer resolution
FDM ABS-M30: ±0.15mm accuracy
MJF PA12: Full color textures
3
Post-Processing & Validation
Surface Finishing
#3 Bead Blasting (Ra 3.2μm)
Chemical Smoothing (ABS/PC)
Class A Automotive Paint
Quality Control
Zeiss CMM: ±0.005mm
CT Scanning (internal voids)
Dye Penetrant Testing
Certification
Material Traceability (RoHS)
First Article Inspection (FAI)
PPAP Level 3 Submission
Technical Highlights
±0.02mm
CNC machining tolerance
24H
Rapid prototyping turnaround
100%
First-article inspection rate
Plastic Prototype Manufacturing Cases
PEEK Surgical Prototype for Medical Device
Surgical Instrument Prototyping
Client Background
Leading medical device startup needed functional prototypes for FDA Class II surgical tools requiring sterilization compatibility.
Technical Requirements
Autoclavable (135°C steam sterilization)
±0.05mm dimensional stability
Biocompatibility (ISO 13485 certified)
Solution
Material: Medical-grade PEEK
Process: 5-axis CNC machining
Lead Time: 7 working days
Results
30% faster regulatory approval
Zero part failure during validation
$15k tooling cost saved
PA66 Connector Prototype for Automotive
Automotive Connector Prototyping
Project Challenge
Tier 1 automotive supplier required 500 functional prototypes of engine bay connectors meeting IP67 rating and 150°C continuous heat.
