Plastic Enclosures for Electronics Projects (Plastics Sourcing Guide)

Table of Contents

• 1. Acrylonitrile Butadiene Styrene (ABS)
• 2. Polycarbonate (PC)
• 3. Polycarbonate + Acrylonitrile Butadiene Styrene (PC+ABS Blend)
• 4. Polyamide (PA) / Nylon
• 5. High Impact Polystyrene (HIPS)
• Extra plastics resources to explore

1. Acrylonitrile Butadiene Styrene (ABS)

Bear in mind that ABS is not particularly good when it comes to retaining its mechanical properties at high temperatures, therefore, the operating environment needs to be considered when selecting this polymer (i.e. it’s not ideal for products that will be in a hot environment or emit too much heat themselves). Having said that, a lot of outdoor-use products do include ABS enclosures but be mindful of the environment the product will be used in.

ABS at a glance

ABS Benefits

• High impact resistance which makes it suitable for applications where knocks and bangs can be expected. Also a good insulator from heat and electricity.
• Excellent surface finish and high gloss can be achieved, so it is a good polymer for higher value products with plastic enclosures.
• Great material for injection molded parts, as it is easy to injection mold and a high level of detail can be achieved.
• Good level of accuracy and dimensional stability as long as it is kept within the working temperature range.
• Can be recycled and reused in molding.
• One of the more cost-effective polymers at just $1.7/lb.

ABS Drawbacks

• Not appropriate for high-temperature environments or working conditions.
• Poor resistance to solvents and other chemicals.
• Will produce toxic fumes when burnt.
• Does not perform well under repeated stress and strain – will fracture over time.
• Limited use for outdoor products as it is affected by UV light.

2. PC (Polycarbonate)

Polycarbonate has excellent toughness properties along with thermal and dimensional stability. No surprise, then, that it is one of the most commonly used engineering plastics used for enclosures that need to withstand harshers conditions ranging from ATM machines, to computer scanners, to bulletproof glass (!). It has the added advantage of being transparent as well as being able to be produced in multiple colors. With its excellent mechanical and physical properties, this is an ideal polymer for both indoor and outdoor applications, especially where transparency and toughness are key (such as many outdoor signs and device screens, for example).

Polycarbonate at a glance

Polycarbonate Benefits

• Excellent impact-resistance makes this plastic perfect for enclosures that need to protect their contents from very rough external conditions and treatment (so tough it is used as bulletproof glass).
• It is lightweight and a good insulator.
• Excellent dimensional stability over a long period of time even at high temperatures.
• Glass-like transparency makes this a unique plastic and perfect for enclosures with gauges and dials behind them that need to be viewed, such as medical devices and automotive instruments.
• Can be produced in large sheet forms that are easily shaped to create large panels that can be assembled, such as for signs or windows.

Polycarbonate Drawbacks

• Scratches easily, making the glass-like finish susceptible to damage and the aesthetics less appealing.
• Can expand and warp under some circumstances.
• It’s one of the more expensive types of plastic enclosures for electronics projects at $2.7/lb.

3. Polycarbonate + Acrylonitrile Butadiene Styrene (PC+ABS Blend)

PC/ABS is a blend of polycarbonate and ABS that provides the best attributes of both polymers as it’s stronger than ABS, but cheaper than PC. This blended polymer provides excellent impact resistance, great thermal resistance, and excellent dimensional stability over extended periods of time. The ability to produce this plastic in any color makes it ideral for product branding and color scheme identification which is why it’s a popular polymer for consumer electronics enclosures such as the vacuum cleaner above. This is also a great material for outdoor applications, however, it does not have very good resistance to some chemicals, so bear this in mind when cleaning.

PC/ABS at a glance

PC + ABS blend Benefits

• With excellent impact-resistance properties this is tough, add to that its cost and this is why it’s one of the most prolifically used plastics worldwide.
• Very good dimensional stability over a range of temperatures and time.
• Excellent surface finishes and high levels of detail are achievable.
• Able to retain its physical and mechanical properties at elevated temperatures over and above that of ABS alone.
• It’s a cost-effective polymer at $1.8/lb.

PC + ABS blend Drawbacks

• Susceptible to chemical corrosion making this plastic unsuitable for enclosures that will be subjected or exposed to any acids, bases, or harsh chemicals.
• PC/ABS plastic is better at resisting UV light than ABS alone, however, it still has fairly poor resistance.
• Limited outdoor use due to poor UV resistance.
• Not the best insulator.

4. Polyamide (PA) / Nylon

Nylon has fantastic wear and toughness properties making it ideal for enclosures that will be subjected to punishment. A great example is the power tool you see above. Tools like this will naturally be subjected to rough handling, drops, etc, during their lifetime! With a high melting point, nylon is also a great selection for hot environments, however, be careful of moisture ingress as it is susceptible to degradation once wet. Therefore, this is also an ideal polymer for plastic enclosures for electronics projects for indoor products.

Nylon at a glance

Nylon Benefits

• High wear resistance provides great durability and makes it ideal for applications with long life expectancies.
• It is static resistant which is favorable for plastic enclosures for electronics projects.
• Able to withstand high temperatures of up to 300 Deg C.
• Easily modified in the raw state to improve its physical and operational properties.
• Good strength and hardness characteristics.
• Very good dampening properties, able to withstand shock loads and vibrations.
• Self-lubricating properties and a smooth surface finishes provide a low friction coefficient.
• It’s one of the more cost-effective polymers at $2/lb.

Nylon Drawbacks

• Poor moisture resistance with physical properties deteriorating over time as the polymer absorbs water.
• Not biodegradable and its manufacturing process has a negative impact on the environment and may not be readily recycled.
• Poor resistance to acids and strong bases.
• Produces a toxic fume when burned with an open flame and it will melt and burn when subjected to, admittedly very high, temperatures.
• Not ideal for outdoor use as it is affected by UV light and water ingress.

5. High Impact Polystyrene (HIPS)

HIPS is a standard non-engineering plastic, has good overall mechanical properties, and is quite similar to the popular ABS. It has good impact strength, stiffness, and insulation properties. It’s also easy to process, has the ability to be produced in large sheet form that can be shaped and assembled, and takes paint and glue well. With poor chemical resistance, but otherwise good resistance to the outdoor elements, this is a good material for outdoor applications. It is also one of the cheapest plastics available and is used in all kinds of everyday applications such as automotive components, refrigerator linings, electrical insulation, disposable yoghurt pots, and many more.

HIPS at a glance

HIPS Benefits

• Withstands high impacts making this plastic very tough and rigid.
• Dimensionally stable over a range of temperatures and long periods of time. Ideal for outdoor use as long as it is protected from UV by painting or coatings.
• HIPS can be produced in large sheet form which can then be reformed to produce large size panels that can be assembled together, perfect for auto parts, for example.
• It is easy to apply paint and other surface coatings for aesthetics or protection purposes, and it can be glued easily.
• The cheapest of the 5 polymers here at $1.3/lb.

HIPS Drawbacks

• HIPS is a flammable plastic so it must not be used in applications where flames will be present.
• Has a poor resistance to solvents.
• Without paint or a coating, it can be negatively affected by UV outdoors.

More plastics resources to explore

First, if you have any questions about plastic enclosures for electronics projects, please ask us any time.

You may also like these resources to help you source the right plastics for your needs:

• Guides and videos about thermoplastics
• The Plastic Injection Molding Process
• Guide To 3D Printing Rapid Prototyping
• 9 Types of Packaging (Benefits, Costs, Sustainability, and more) guide for Importers – including plastics!
• Related – 11 Common Electronic Product Certification And Compliance Requirements