Engineering Plastics for Prototype Manufacturing

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.

Key Advantages

  • High impact strength
  • Good chemical resistance
  • Easy post-processing

Technical Specifications

Tensile Strength
40 MPa
Temperature Range
-20°C to 80°C
Density
1.04-1.07 g/cm³
Price Range
$0.5-$0.8/cm³

Typical Applications

Automotive dashboardsPower tool housingsPrototype validation

POM (Acetal) Prototypes

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.

Key Advantages

  • Optical transparency
  • UV resistance
  • Flame retardant

Technical Specifications

Tensile Strength
65 MPa
Temperature Range
-135°C to 135°C
Density
1.20-1.22 g/cm³
Price Range
$1.0-$1.5/cm³

Typical Applications

Safety gogglesMedical equipmentAerospace components

PA (Nylon) 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

MaterialTensile (MPa)Max TempPrice RangeMachinability
ABS40 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
PEEK100 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

MaterialSpeed (m/min)Feed (mm/tooth)Tool Type
ABS200-3000.08-0.122-flute carbide
PEEK120-1800.05-0.08Diamond-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

Medical plastic prototype manufacturing case - PEEK surgical instrument
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
Automotive plastic prototype manufacturing - PA66 engine connector
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.

Implementation

Material: Glass-filled PA66Tolerance: ±0.1mm Surface Finish: VDI 3400

Manufacturing Process

  1. 1DFM analysis for injection molding conversion
  2. 2Multi-cavity CNC machining with P20 steel
  3. 3UL94 V-0 flame testing certification

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