Plastic Playbook: Choosing The Right Polymer

Choosing the right polymer for your plastic parts can significantly impact the success of your product. In this episode, Adrian and Paul Adams from Sofeast explore the most common polymers used in manufacturing, from everyday workhorses like ABS to high-performance engineering plastics and sustainable bioplastics.

They cover the strengths, weaknesses, and real-world applications of each group, plus share a cautionary case study where a material change led to product failure. The episode wraps up with advice on additives, testing, and key considerations to ensure your material choice supports your product’s success.

 

Episode Sections:

• 00:00 – Introduction
• 00:55 – Why Polymer Selection Matters
• 04:49 – ABS and Its Blends – The Workhorse Polymer
• 08:27 – Commodity Polymers – PP, PC, HDPE
• 16:20 – Engineering Polymers – Nylon, POM, PCTG
• 26:19 – Case Study: A Costly Material Change
• 32:42 – Flexible & Sustainable Options
• 38:42 – Key Additives and Modifiers
• 40:17 – Wrap-Up and Key Takeaways

 

Need help choosing the right polymer for your product? Sofeast’s product engineering team supports you from design through to production: Contact us for a conversation.

 

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Polymer Selection Guide: Summary Table
Polymer Family	Key Strength & "Personality"	Typical Tensile Strength (MPa)	Typical Impact (Izod, J/m)	Key Limitations	Best For Applications Like...
COMMODITY / WORKHORSE POLYMERS
PP (Polypropylene)	The Low-Cost Champion	25 - 40	20 - 80	Poor UV resistance, difficult to bond, can be brittle with fillers.	Food containers, living hinges, consumer goods, automotive interiors.
	Lightweight, chemical resistant, versatile.
HDPE (High-Density Polyethylene)	The Chemical & Moisture Barrier	20 - 30	40 - 200	Low strength and stiffness, poor temperature resistance.	Milk jugs, shampoo bottles, chemical tanks, food-safe packaging.
	Excellent chemical resistance, moisture barrier, food-safe.
ABS (Acrylonitrile Butadiene Styrene)	The All-Rounder	40 - 50	200 - 400	Poor UV and weather resistance, low heat resistance.	Electronic housings, automotive trim, consumer product shells, LEGOs.
	Best balance of strength, rigidity, impact, and surface finish.
ENGINEERING / PERFORMANCE POLYMERS
PC (Polycarbonate)	The Impact-Resistant Shield	55 - 75	600 - 850	Prone to scratching, susceptible to chemical stress cracking.	Safety glasses, bullet-resistant windows, transparent machine guards, electronic covers.
	Exceptional impact strength, transparent, high heat resistance.
PC+ABS Blend	The Balanced Hybrid	45 - 55	300 - 500	Properties are a compromise; not as good as pure PC or ABS in their top traits.	Automotive dashboards, laptop housings, power tool bodies.
	Perfect balance of PC's strength/heat and ABS's processability/finish.
PA (Nylon / Polyamide)	The Strong & Tough Workhorse	80 - 120*	40 - 150	Absorbs moisture, which affects dimensions and properties.	Gears, bearings, automotive under-hood parts, mechanical components.
	High strength, stiffness, wear resistance, and heat resistance.	(with 30% GF)
POM (Acetal)	The Precision Engineer	60 - 70	60 - 120	Poor resistance to strong acids and bases.	Precision gears, conveyor belts, fasteners, zippers, fuel systems.
	High stiffness, low friction, excellent fatigue resistance.
PCTG (Tritan™)	The Tough & Safe Transparent	50 - 55	700 - 900	Higher cost than PC or ABS.	Medical devices, baby bottles, small appliances, drinkware.
	High clarity, excellent impact/chemical resistance, BPA-free.
FLEXIBLE / ELASTOMERIC POLYMERS
TPE (General)	The Soft & Squishy Gripper	20-Oct	N/A (Elongation: 300-600%)	Lower durability and chemical resistance than TPU/TPV.	Soft-grip handles, bottle stoppers, squeezable toys.
	Soft, flexible, easy to process, cost-effective elastomer.
TPU (Thermoplastic Polyurethane)	The Abrasion-Resistant Tank	25 - 35	N/A (Elongation: 400-600%)	Can be susceptible to humidity during processing.	Phone cases, watch bands, athletic shoe soles, protective covers.
	Extreme abrasion and tear resistance, tough, flexible.
TPV (Thermoplastic Vulcanizate)	The Weather-Resistant Seal	15-Oct	N/A (Elongation: 300-500%)	Softer, less rigid than TPU.	Automotive seals & gaskets, weather-stripping, outdoor hose coatings.
	Excellent heat, weather, and UV resistance like traditional rubber.
SPECIALTY / SUSTAINABLE POLYMERS
PLA (Polylactic Acid)	The Sustainable Candidate	50 - 70*	15 - 30 (Brittle)	Very brittle, low heat resistance, degrades in humid environments.	Disposable cutlery, packaging, 3D printing filament (prototyping).
	Biodegradable, bio-based, rigid.	(highly variable)

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