Plastic Vs.

Metal Fabrication - Advantages

and Disadvantages
Fabrication refers to any process that cuts, shapes, or otherwise forms a material
into an end product. The type of fabrication method used to produce a particular
item depends on a wide range of factors, including the products purpose,
appearance, and available budget. Before determining whether plastic or metal
fabrication is appropriate for a particular job, it is important to first understand the
potential advantages and disadvantages of each option.

Types of Fabrication Processes

Both plastic and metal fabrication involve a wide range of distinct manufacturing processes.
This range allows for a considerable number of customization and selection options in
component design. Some of the more common fabrication processes include:

• Cutting: This involves various tools or machines removing excess material from a workpiece to
meet size and shape requirements. Band saws and cutting torches are two examples of cutting
devices.
• Forming: This process uses deforming equipment, such as hydraulic brakes, to bend or press
products at a specified angle.
• Machining: Machining processes, which include lathing, milling, drilling and honing, use
automated or manually controlled equipped to shape material.
• Welding: Welding is the process of joining two or more workpieces by applying heat or
pressure to form a single product.

Advantages of Plastic Fabrication

Though the results of plastic fabrication greatly depend on the

unique characteristics of the type of plastic used (acrylic,
Plexiglas, nylon, etc.), the process itself has several advantages,
which include:

• Ease of forming: Due to its low melting point and high

malleability compared to other materials, plastic can be formed
into basic and complex geometries with relative ease.
• Reduced finishing: Unlike most metals, plastics can be colored
prior to fabrication, eliminating the need for certain post-
treatment processes, such as painting.
• Faster production: Plastic fabrication often involves quick cycle times and fast
turnover rates.
• Lighter weight: Plastics typically weigh less than metals of comparable dimensions.
• Chemical resistance: Plastics are generally less susceptible to damage from
chemicals or chemical reactions, such as oxidation or rusting, than metals.

Disadvantages of Plastic Fabrication

Although plastic is useful for fabricating a wide range of parts, it also has its share of
limitations as a production material. Some of the disadvantages of plastic fabrication
include:

• Limited wear resistance: Plastic has a low resistance threshold for elevated
temperatures, acidity, and other corrosive elements.
• Structural weaknesses: Most plastics are unsuited for applications requiring high
structural strength, such as heavy equipment components and most building
materials.

Advantages of Metal Fabrication

Like plastic fabrication, metal fabrication depends largely on

the family and grade of metal used in production. Some of
the more commonly fabricated metals include steel,
magnesium, iron, aluminum, copper, and nickel, each with
their own various grades. Metals generally provide the
following advantages over plastic fabrication:

• Heat resistance: Metals typically have a higher melting-

point and are less likely to degrade under elevated
temperatures.
• Improved strength: Metal grades tend to be stronger,
harder, and more durable than their plastic counterparts.
• Versatility: Metal can be fabricated through a wider range of processes, including
casting, deep drawing, welding, forging, soldering, and chipping.
• Cost-effectiveness: Metal is usually a cost efficient option, particularly in high-
volume or long-term production runs.

Disadvantages of Metal Fabrication

Despite offering numerous benefits, metal is not ideal for every application. Some of
the disadvantages of metal fabrication include:

• Secondary operations: Metal fabrication is more likely to require post-fabrication

processes, such as finishing, painting, and deburring, which can be time-consuming
or costly.
• Design limitations: The viscosity and molten flow behavior of some metals are not
suited for crafting highly complex geometries or shapes.
• High start-up fees: metal tooling costs are typically more expensive than
comparable plastic fabrication tooling.

Choosing a Specific Fabrication Process

Once you have determined whether plastic or metal fabrication will better meet your
project needs, the next step in the production process is to choose a specific shaping
or forming process. Some frequently used fabrication techniques and their common
applications are:

• Lathing: Lathing is a cutting method that uses a rotating work table and separate
blade to cut, drill, knurl, or etch the material. Lathing is best suited for products that
are symmetrical around an axis of rotation.
• Drilling: This process employs a drill press to bore holes into a product. It is
effective for creating uniform, circular cuts.
• Milling: Like drill presses, mills bore holes through material, but with a sideways
cutting motion. They are a good option for creating asymmetrical or non-circular
cuts.
• Honing: Honing involves multiple rotating tips that enlarge existing holes to exact
sizes. It is useful for making products that require large circular cuts, such as engine
cylinders.
• Grinding: Grinders apply an abrasive wheel to surface treat material or create faint
cuts in the product. Grinding is beneficial for applications that require smooth
surface textures.
 Plastics / Composites Specific Gravity
Acetal copolymer 1.41
Acetal, 20% glass composite 1.55
High-impact ABS 1.03
Polycarbonate 1.19
Polyethermide 1.27
Polymethylpentene 0.83
Metals Specific Gravity
Aluminum 2.55 – 2.80
Carbon Steel 7.8
Cast Iron 7.03 – 7.13
Cast Rolled Brass 8.4 – 8.7
Copper 8.89
Stainless Steel 7.7
Titanium 4.5
Tool Steel 7.70 – 7.73
Tungsten Carbide 14.29
The Specific Gravity – SG – is a dimensionless unit defined as the ratio of density of the
material to the density of water at a specified temperature.

Factors to Consider When Choosing the Right Material for Your Product
Much of the prolific growth in the plastic industry over the past several decades has been
fueled by the replacement of metal products and components. Examples are numerous, and
include canoes, airplane parts, medical implants, missile components, gas cans, and car parts.
Along the way, many designers have had to evaluate whether to use plastic or metal in their
applications. Below are some of the considerations that may be helpful.

PLASTIC: THE ADVANTAGES

 Weight: Plastic can weigh appreciably less than metal, which can translate to savings in
several ways. A plastic part could easily weigh one-sixth of the same part in steel or half the
weight of aluminum.
 Chemical Resistance: Plastics are much less likely to suffer chemical attack, and they will not
corrode.
 Machinability: Plastic is easier to cut through, which makes the process of machining parts
quicker.
 Dent resistant (see car bumpers).
 Eliminates painting process: Translucent or colored parts can be produced without the
secondary operation of painting needed for metal parts.
 Design: Complex designs, shapes, lettering, and surface textures can be incorporated into the
tooling made to manufacture plastic parts.
 Quality: For high volume production, the tooling for molded plastic parts offers very
repeatable quality compared to machined metal products.
 Product Life: The life span is longer for plastics than metals in many applications.
 Cost: The cost of raw material can be appreciably less. With a less labor intensive process,
plastic molding can also save energy, labor, and production time vs. metal processes.
 Noise: The sound of plastic against plastic is less intrusive than metal against metal.
 Options: There are hundreds of different plastics available to meet specific applications. The
choice of metals is much more limited.

PLASTIC: THE DISADVANTAGES

 High heat can cause plastic to degrade.

 Thermal expansion and shrinkage is greater than metal.
 Ultraviolet light can degrade plastic. An ultraviolet inhibitor is often added for outdoor applications.

METAL: THE ADVANTAGES

 Thermal and electrical conductivity is greater.

 Strength: Metal is generally stronger.
 Versatility: Metal can be used in more extreme temperature applications.

METAL: THE DISADVANTAGES

 Machinability: Metal is more difficult to machine.

 Secondary operations are more likely to be needed (i.e. polishing, deburring, painting, etc.).
 Susceptibility to oxidation and corrosion

-Weight is a big reason parts are transitioned from metal to plastic, as they’ve been in planes
and cars for many years.
Pictured are two heating trays. One is made from metal and is a standard item in home
kitchens. The other is plastic, and is typical of those used in fast food restaurants, which
formerly used metal. Why the switch? The plastic version is quieter to work with, lighter,
and colors can be used to differentiate food items.
The decision of which material to use is all about the specific application. Strength
requirements, number of parts needed, chemical exposure, ultraviolet exposure, and
temperature are among the important considerations. It may be appropriate to look at several
different metals and plastics.
 For your small custom parts and fasteners, we can help you with your decision. Craftech has 50
years of experience with many dozens of different plastic resins – and we have both machining
(small volume) and injection molding (large volume) capabilities

Physical and chemical properties

Aluminium is a soft, silvery light metal. It is very reactive so that in the atmosphere a thin but equally
protective oxide layer forms rapidly. For this reason it is very resistant to corrosion. By a special
treatment, anodizing, i. e. an electrolytic oxidation process, the aluminum surface protected by the
oxide layer can even be strengthened and made more resistant to corrosion.

Aluminium reacts strongly with hydrochloric acid and caustic soda. The reaction with sulfuric acid is
weaker, while it remains passive in contact with cold nitric acid.

Aluminium possesses good thermal and electrical conductivity, in each case about two-thirds of the
values for pure copper. Due to its electronic configuration the element has three valency electrons; its
oxidation number is therefore +3.

 Melting point: 660 °C (for AL 99,99 acc. to composition / alloying higher resp. lower)
 Boiling point: 2500 °C (acc. to composition / alloying higher resp. lower)
 Density: 2,70 g/cm³
 Relative atomic mass 26,98
 Oxidation number: 3
 Atomic radius: 143,1 pm
 Ionic radius: 57 pm (+3)
 Electrical conductivity: 36 m/Ohm·mm²

Physical Properties of Aluminum

Aluminum is silvery-white in color. It melts at 1220.576 Fahrenheit and boils at

4472.33. Aluminum has an atomic weight of 26.98154, and an atomic radius of 143.1
pm. It is one of the most ductile and malleable metals. Aluminum is non-magnetic.

Chemical Properties of Aluminum

When it comes in contact with oxygen, aluminum forms an oxide skin called aluminum
oxide. This skin helps to protect aluminum from corrosion. Aluminum catches fire
easily if exposed to flame when it is in powdered form. It is also reactive with both
acids and alkalis.
Uses of Aluminum

The physical and chemical properties of aluminum make it an ideal metal for making
such products as culinary utensils, automotive parts, construction materials, and food
and beverage containers.

Atomic number 13

Atomic mass 26.98154 g.mol -1

Electronegativity according to Pauling 1.5

Density 2.7 g.cm -3 at 20 °C

Melting point 660.4 °C

Boiling point 2467 °C

Vanderwaals radius 0.143 nm

Ionic radius 0.05 nm

Isotopes 3

Artificial isotopes 16

Electronic shell 1s2 2s2 2p6 3s2 3p1

Energy of first ionization 577.4 kJ.mol -1

Energy of second ionization 1816.1 kJ.mol -

Energy of third ionization 2744.1 kJ.mol -1

Standard potential - 1.67 V

Discovered by Hans Christian Oersted in 1825

Some applications work only in metal and others only in plastic. Many, however, occupy a
large middle ground in which either will work. At such times, plastic is often the material of
choice given its many benefits.

Compared to metal, plastic can reduce weight, dampen sound, create more complex parts,
and eliminate secondary steps such as machining and coating. Some plastics resist
corrosion and chemicals better than many metals even as they retain the strength of cast
metals at elevated temperature.

The design of a plastic part to replace a metal one should proceed from the general to the
specific. Begin by understanding the mechanical, environmental, thermal, electrical, and
other conditions it will encounter over its life, as well as how it will be processed and
assembled. Initial decisions on material, detailed design, processing, and fabrication evolve
from this understanding and are essential for deriving preliminary costs.

In estimating costs, account for the direct material and manufacturing outlays, as well as
those buried in overhead. A plastic part can often combine two or more metal parts,
reducing inventory, labor, production floor space, assembly time, energy, and other
elements. As the part component evolves from concept to production, the choice of resin,
design, processing and assembly methods, and associated costs should be evaluated
repeatedly.

Design in plastic, especially for metal replacement, should be guided by a team that
combines production, design, engineering, research, sales, marketing, and purchasing
expertise. For added depth, it can include members from the plastics supplier, molder, tool
builder, and assembly equipment manufacturer. Plastics suppliers, for instance, help in
understanding resin performance and assist with design, prototyping, molding, and pre-
production evaluations.

Resin Selection
Designers face many choices in replacing metal. Plastics, which range from commodity to
high-performance resins, encompass thousands of options depending on their chemistry,
chain length, and structure, and bonds between chains. Neat resins are modified by alloying
different plastics together and by blending in additives, fillers, and reinforcements to alter
impact, mechanical strength, stiffness, shrinkage, warpage, lubricity, and much more.

More demanding applications require engineering polymers in which price and performance
tend to rise in unison. Higher performing resins generally can bear greater loads and
thermal stress. They also tend to withstand acids, bases, solvents and other chemicals
better, as well as resist the cracking, crazing, discoloring, softening, and melting such
substances can cause.

The trick is to choose a resin that gives the best performance at the lowest price. To start,
map the conditions a part will meet during processing, assembly, end use, and even
recycling. In assembly, for example, the material must match the method used. Some
resins are compatible with solvent bonding or ultrasonic welding and others work best with
snapfit designs that require strength, flexibility, and dimensional stability.

Although a plastic may cost more than the metal it replaces – especially higher performance
grades – they can make production far more efficient and cost less overall. A good example
is the use of high-flow resins that allow for thinner, more complex parts that eliminate
machining and other secondary operations needed with metals.
Part Design
Design in plastic calls for a different mindset than design in metal. They are fundamentally
different materials and so are processed and assembled differently. Most plastic parts are
injection molded because this process is economical, efficient, precise, and produces
finished parts in an automated operation. Compared with metal die-casting, injection
molding is faster and offers longer mold life. Diecast molds usually last less than 100,000
cycles, while injection molding tools routinely withstand more than 4 million cycles before
needing major maintenance.

In designing injection molded parts, their walls should be uniform (usually 0.8 to 5.0 mm
thick) and as thin as possible to reduce weight and cycle time yet still meet mechanical and
appearance specifications. The design should consider draft (a slight taper in the part) and
avoid heavy masses of plastic that can extend cycle time and lead to moldedin stresses and
distortions.

The part should have generous radii where elements intersect in order to reduce stress
concentrations. Ribs and gussets can be used to buttress areas and add strength and
stiffness without thickening walls. Multiple, evenly spaced ribs generally distribute the load
better than large, isolated ones. Ribs should be as thin as possible when opposite visible
areas so sink marks don’t form. Designers can also use sculpted surfaces to aid structural
integrity.

Bosses are added to aid assembly. These helping components align with each other and act
as mounting or fastening points. Openings, pockets, and blind holes can eliminate heavy
sections or provide for mounting.

Mold and Tool Design

Many factors come into play that are often minimal when working with metal. The resin,
part design and assembly method affect mold and tool design and are, in turn, affected by
it. Wall thickness, for instance, influences a mold’s cooling system and the number of tool
cavities, while surface finish determines if the mold must be polished or textured. In
addition, the need to limit residual stress in the part impacts gating, the cooling system and
runner design.

The mold should allow as broad a processing window as possible so resin properties and
process variables, such as viscosity, hydraulic pressure, barrel temperature, and even
longterm screw and barrel wear, can shift over time without harming part quality. Tool
design encompasses such features as gating, cavities, draft, runners and slides, all of which
can affect processing window and part quality.

Gate type, size, and position are chosen to aid part strength and appearance, resin
alignment, mold filling time and resin flow length, among other factors. Tools usually have
more cavities in high production situations and fewer cavities when finer tolerances are
needed.

Draft usually involves tapers of 0.5 to 3 degrees. It allows parts to eject more easily from
the mold and is affected by the position of the mold parting line, the length of a projection
and part texture.
In terms of runners, a conventional system that operates without added heat can generate
a large amount of scrap, which is often be reground and reused. Hot runners yield little or
no scrap, but cost more and are more complex to operate. They are useful when runner
volume is large relative to part size.

Some parts need complicated molds that call for expensive unscrewing or collapsing cores,
slides, multiple plates, or intricate parting lines.

Computerized finite-element analyses can reduce mold development time and cost. These
numerical tools include mold filling analysis, which evaluates gating position and size for
optimum flow, the location of weld lines, and other factors, as well as cooling analysis,
which looks at mold temperature distribution and cycle time and shrink analysis, which
evaluates dimensional control, moldedin stresses and warpage.

The nature of the plastic used also affects part and mold design. Viscosity helps determine
flow length in the cavity, gate placement, and mold cavity cooling. A resin’s ability to
transfer heat affects the cooling system and its ability to prevent warpage and ensure
optimum resin characteristics.

How much a resin shrinks as it cools is important because mold cavities are sized so part
dimensions fall within the tolerances set. The filler present and its alignment also affect
shrinkage, because it can cause more shrinkage in one direction than in another. Shrinkage
also depends on part thickness and geometry.

Assembly
Design in plastic should limit the number of secondary steps needed to complete a
component. When a component is switched from metal to plastic, designers often find they
consolidate two or more parts into one because molding allows for more complexity. Such
consolidation is the most effective assembly method, since it joins parts in the mold. When
combining two or more parts into one, the added mold complexity should not outweigh the
savings due to the reduction in assembly steps.

Design should also make use of moldedin features that eliminate the welding, drilling,
painting, thread tapping, and other secondary operations needed with metals. Efficiency can
be improved by considering various assembly strategies, such as selecting an optimum
joining method and minimizing the possibility of mating mistakes.

Moldedin joining systems, such as snapfits and pressfits, are fast, inexpensive, and avoid
additional parts. Chemical bonding by solvent welding or adhesives creates air-tight gas
seals and can be used when fasteners are impractical. Welding, via ultrasonic, vibration,
spin, electromagnetic, or thermal methods, is fast and safe but requires similar materials.
Mechanical fasteners, such as bolts, screws, rivets, and spring clips, are easy to use and
allow nondestructive disassembly but require additional parts and can be labor intensive.

Plastics components can be made to exacting tolerances as they emerge from the mold,
secondary sizing operations are not needed as if often the case with metal. Tolerances
determine the precision needed in mold tooling, assembly and finishing. Special care is
needed with if tolerances are tight, because the variations in each processing step, such as
mold filling and cooling, are additive and can cause a loss of critical dimensions if they are
not controlled carefully.

Final design
The initial design of a plastic part creates a theoretical part. Subsequent analyses,
simulations, and prototyping evaluate how well the part works in the intended use and
provides essential feedback to refine the design. Computerized design tools, including
computeraided design, engineering and manufacturing (CAD, CAE and CAM) software, help
finalize the part.

CAE, for instance, determines optimum geometry by evaluating direct loads or deflections.
It often proceeds from classical equations to nonlinear effects to give increasingly accurate
estimates of how the stresses encountered during processing, assembly, shipping and end
use will affect a part. These evaluations aid the final decisions made on materials,
processing and such design elements as walls, ribs, draft and radii.

Prototypes are often used to test essential properties, verify design and highlight assembly
issues. They also enable customers to respond to the part concept. Prototypes can use the
same material and manufacturing process as will be used for the finished part or the same
material and a different process. The latter has different properties than a molded model.
The least exact method replicates part geometry from a different material and a different
process, such as stereolithography.

Plastics have grown increasingly sophisticated in recent decades, and so have been
adopted for a widening range of demanding applications traditionally met by metals. Plastics
have been adopted in many markets because they reduce weight, take more complex
shapes, withstand environments many metals cannot tolerate, reduce total costs and much
more. This has led to great diversity in how plastics are used and created a solid track
record for the use of plastics instead of metal in many markets, including autos, trucks,
airplanes and other areas of transportation, medical devices and instruments, appliances,
electrical and electronic components, and office and industrial equipment.