ABS vs PC: Complete Engineering Comparison (2026) — Temperature, Strength, Cost

Which Material Should You Choose?Choose ABS (Acrylonitrile if:Cost-sensitive housings, automotive interior trim, consumer appliance enclosures, luggage shells where moderate impact resistance is sufficientChoose PC (Polycarbonate) if:High-impact...

ABS and Polycarbonate are two of the most widely used amorphous engineering thermoplastics, and they compete directly in housing, enclosure, and structural part applications. The choice between them is typically driven by three factors: impact requirement, temperature requirement, and budget.

When to choose ABS: ABS is the workhorse of consumer product enclosures — it is the default material for appliance housings (vacuum cleaners, power tools, kitchen appliances), automotive interior trim (instrument panels, door panels, center consoles), consumer electronics enclosures (keyboards, printers, router housings), and luggage shells. ABS offers an excellent balance of rigidity (flexural modulus 2.0-2.5 GPa), moderate impact strength (notched Izod 200-400 J/m), and superior surface finish — it is the best substrate for chrome plating among engineering thermoplastics and accepts paint, texture, and printing with minimal preparation. ABS processes easily at melt temperatures of 220-260°C with mold temperatures of 50-80°C, with low mold shrinkage (0.4-0.7%) and excellent dimensional stability. At $1.50-2.50/lb, ABS is 30-40% less expensive than PC.

When to choose Polycarbonate: PC is specified when ABS's impact strength or heat resistance is insufficient. PC's notched Izod impact of 600-900 J/m is 2-4× higher than ABS, and PC is virtually unbreakable at room temperature — it does not exhibit the brittle fracture seen in ABS at low temperatures. This makes PC the standard for safety-critical applications: hard hats, safety goggles, face shields, and bullet-resistant glazing (laminated PC sheets). PC's other key advantage is inherent transparency — it has 87-91% light transmission, making it the material of choice for transparent enclosures, electronic display windows, LED light diffusers, and medical device housings where internal component visibility matters. PC's HDT of 130°C at 1.82 MPa (vs ABS's 95°C) extends the service temperature envelope significantly — PC housings survive internal electronics generating more heat without deforming.

PC/ABS blend — the best of both: When neither pure ABS nor pure PC is optimal, PC/ABS blends (typically 50-70% PC / 30-50% ABS) offer a compromise: higher impact than ABS, lower cost than PC, and better processability than PC. PC/ABS is the most common material for laptop housings, mobile phone cases, and automotive interior components requiring higher heat resistance than ABS alone. PC/ABS HDT of 110-125°C bridges the gap between ABS (95°C) and PC (130°C).

Limitations to consider: ABS becomes brittle below -20°C and is unsuitable for cryogenic or cold-climate outdoor applications without impact modifiers. PC has notch sensitivity — sharp internal corners or metal inserts create stress concentrations that dramatically reduce impact strength. PC also suffers from environmental stress cracking when exposed to certain solvents (gasoline, acetone, methylene chloride) — a limitation ABS shares but to a lesser degree for some solvents. Neither material is suitable for continuous UV exposure without stabilization.

Comparison at a Glance

Related Diagnostics & Materials

References & Industry Standards

• ASTM International. Standard Specifications for Engineering Plastics & Thermoplastics. astm.org
• UL Prospector. Plastics & Elastomers Material Database. ulprospector.com
• MatWeb. Material Property Data for Engineering Thermoplastics. matweb.com
• ISO 1043. Plastics — Symbols and Abbreviated Terms. iso.org