Plastics for Consumer Products
ABS, PC, PP, PA, TPU — the five letters that define what your product feels like, costs, and how long it lasts. Pick the wrong one and no mold design can save you.
Plastic selection is the most consequential material decision in consumer product design. The right plastic disappears into the product — it performs, looks right, and does not cause returns. The wrong plastic fails quietly: a crack at the boss, a brittle snap-fit, a surface that scratches on day one.
For hardware founders, the challenge is that plastics all look the same in pellet form. The differences only surface in the finished part — and by then, you have already paid for the mold. Understanding the major families of engineering plastics before you commit to tooling is not optional.
ABS is the workhorse. It is tough, impact-resistant, takes color well, and molds easily. It is the default choice for consumer electronics housings, appliance shells, toys, and automotive interior trim. ABS is not UV-stable — if your product lives outdoors, you need ASA instead. It is also not transparent (though you can get translucent grades). Cost: moderate.
Polycarbonate (PC) is the transparent tough option. It is used for safety goggles, blender jars, LED light covers, and anything needing glass-like clarity with impact resistance. PC flows less easily than ABS — mold design needs larger gates and higher temperatures. It scratches more easily than glass and is sensitive to certain chemicals including some cleaning agents. Cost: moderate to high.
Polypropylene (PP) is the value champion — cheap, chemically resistant, and flexible. It is the material of living hinges (flip-top caps, clamshell containers) because it can flex thousands of times without breaking. PP has a waxy surface feel and does not accept paint or adhesives well without surface treatment. It has low density, so parts feel light — which can be good or bad depending on your product. Cost: low.
Nylon (PA, polyamide) is the wear-resistant option. It is used for gears, bearings, structural components, and anything that needs mechanical strength under repeated load. PA absorbs moisture from the air — a PA part that fits perfectly in a dry factory may swell and seize in a humid bathroom. Design with moisture conditioning in mind. Glass-filled PA (PA66-GF30) dramatically increases stiffness and heat resistance. Cost: moderate to high.
TPU and TPE are the soft-touch materials. They give overmolded grips, flexible cases, watch bands, and gaskets their rubber-like feel. TPU has excellent abrasion resistance. TPE is softer and cheaper but less durable. Both can be overmolded onto rigid plastics like ABS or PC in a two-shot process for premium soft-touch products. Cost: moderate.
Material selection mistakes that destroy products
Using ABS outdoors without UV stabilization
Standard ABS yellows, becomes brittle, and cracks within months of sun exposure. If your product sees sunlight, spec ASA or UV-stabilized ABS. Check with your material supplier.
Specifying PC without considering chemical compatibility
PC cracks when exposed to common cleaners, solvents, and even some adhesives. Test your material against every chemical the product will encounter — including packaging adhesives.
Ignoring moisture absorption in nylon parts
PA 6 can absorb up to 3% of its weight in water. A tight-fitting gear in a dry factory may bind completely in a humid bathroom. Design your tolerances for the conditioned state.
Choosing a material the factory does not actually stock
A specialty grade from a datasheet may have a six-week lead time and a 1-ton MOQ. Verify material availability with your factory before finalizing your BOM.
Overlooking surface finish compatibility
Not every plastic takes paint, plating, or laser etching equally. PP needs flame or plasma treatment. TPU resists most coatings. Confirm your finishing process with the material supplier.
What founders should remember
ABS is the default starting point
If you do not have a specific reason to use another material, start with ABS. It is versatile, forgiving, and every injection molding factory knows how to run it.
Ask for the material datasheet, not just the name
"ABS" covers hundreds of grades with different flow, impact, and UV properties. The datasheet tells you what you are actually buying. Your factory should provide this on request.
Test your material in the intended environment
A sample that looks perfect on a desk may fail in a hot car, a steamy bathroom, or after one dishwasher cycle. Environmental testing catches what datasheets cannot predict.