Plastic vs metal.
Material decision.
When each wins.
Plastic vs metal material decision. Each has strengths. Plastic light/cheap/insulating. Metal strong/conductive/durable. Combined often optimal.
Key principles.
Light, cheap, insulating
Lower density, lower cost, electrical insulation. Cosmetic versatility.
Strong, conductive, durable
Higher strength, stiffness, conductivity, temperature, durability.
Plastic cheaper
Plastic generally cheaper, especially at production volumes via molding.
Plastic lighter
Plastics 0.9-2 g/cm³. Metals 2.7-19 g/cm³.
Metal higher
Most plastics limited to 100°C. PEEK to 250°C. Metals unlimited.
Plastic limited
Metal infinitely recyclable. Plastic limited cycles.
FAQ
When plastic over metal?
Weight-sensitive, cost-sensitive, electrical insulation, complex molded geometry, consumer products.
When metal over plastic?
High strength, high temperature, electrical conductivity, durability, structural applications.
Hybrid construction?
Common — plastic enclosures with metal structural inserts. Best of both.
Cost crossover?
Plastic cheaper at production volumes. CNC metal vs CNC plastic similar.
Environmental impact?
Metal infinitely recyclable. Plastic 1-3 cycles before degradation. Both have impacts.
Future trends?
Composites (carbon fiber + epoxy) bridging properties. Replacing metal in aerospace.
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