Common Injection Molding Materials: The Complete Engineering Guide to Plastic Selection, Processing & Mold Design

📌 Engineering Summary – Key Takeaways

  • Selecting the right material is one of the most critical engineering decisions – it affects product durability, manufacturing cost, mold design, and long-term reliability.
  • 11 materials fully profiled: ABS, PP, PC, PA6, PA66, POM, PMMA, PBT, TPU, PPS, and PEEK – each with properties, processing parameters, shrinkage data, and applications.
  • Material classification: Commodity plastics (PP, PE) for low cost; engineering plastics (ABS, PC, PA, POM, PBT, PMMA, TPU) for balanced performance; high-performance plastics (PPS, PEEK) for extreme environments.
  • Shrinkage varies significantly: ABS 0.4-0.7%, PP 0.8-2.0%, PC 0.5-0.7%, PA66 1.0-2.0%, POM 1.5-2.5% – mold design must compensate accordingly.
  • Processing parameters matter: Each material has specific melt temperature, mold temperature, and drying requirements – using incorrect parameters causes defects.
  • Material choice affects mold design: Different shrinkages, flow characteristics, cooling requirements, and glass fiber orientation affect gate design, cooling layout, and steel selection.
  • Total cost of ownership (TCO): Material cost + processing cost + cycle time + scrap rate + tool wear + warranty cost – cheapest resin is not always lowest total cost.

Bottom line: The best material is not the strongest or the cheapest – it is the one that provides the required performance at the lowest total manufacturing cost. Use a systematic selection process: define requirements → shortlist candidates → prototype test → DFM review → production validation.

1. Introduction

Selecting the right injection molding material is one of the most important engineering decisions during product development. Many companies focus heavily on mold design, manufacturing processes, and production equipment, but the selected plastic resin often determines whether a product will succeed or fail in real-world applications.

A plastic component is not simply a shape created by a mold. It is an engineered material system that must withstand specific mechanical loads, environmental conditions, manufacturing processes, and customer expectations.

The same product geometry manufactured with different materials can have completely different performance characteristics:

  • A PC housing may survive high-impact environments where ABS fails.
  • A POM gear may operate thousands of cycles where general-purpose plastics wear quickly.
  • A PA component may provide excellent mechanical strength but require moisture management due to water absorption.
  • A PEEK component may outperform standard engineering plastics in extreme temperatures but significantly increase material cost.

Material selection affects: product durability, mechanical performance, dimensional accuracy, mold design complexity, production efficiency, manufacturing cost, regulatory compliance, and product lifecycle reliability.

Choosing the wrong material early can create expensive consequences after tooling begins: mold modification, unexpected shrinkage, warpage problems, poor surface appearance, assembly failures, product recalls, and increased warranty costs.

Engineering insight: Professional product developers do not select plastics only based on material price or availability. They evaluate the complete relationship between Material Properties + Product Requirements + Manufacturing Process + Lifecycle Cost.

After reading this guide, you will understand: how injection molding materials are classified; differences between commodity, engineering, and high-performance plastics; how ABS, PP, PC, PA, POM, PBT, TPU, PMMA, PPS, and PEEK compare; how material properties affect mold design and production; how to evaluate shrinkage, processing requirements, and cost; how to select materials using an engineering decision process; and common material selection mistakes to avoid.

2. Why Does Material Selection Matter in Injection Molding?

Material selection influences almost every stage of product development. A common misconception is that once the CAD design is completed, the material decision becomes a secondary consideration. In reality, material selection should happen before finalizing part geometry, mold structure, gate design, cooling system, and production strategy. The selected resin affects not only the final product but also the entire manufacturing process.

2.1 How Does Material Selection Affect Product Performance?

Different plastics provide different combinations of tensile strength, impact resistance, stiffness, flexibility, fatigue resistance, wear resistance, heat resistance, and chemical resistance. For example: a protective enclosure used in industrial equipment may require high impact resistance, flame retardancy, and chemical resistance. A precision gear requires low friction, dimensional stability, and wear resistance. A transparent optical cover requires high transparency, scratch resistance, and optical stability.

There is no universal “best plastic.” The correct material depends on the product function.

2.2 How Does Material Selection Influence Mold Design?

Plastic materials behave differently during injection molding. Important material characteristics include:

Shrinkage Behavior: All plastics shrink during cooling. However, shrinkage varies significantly between materials.

MaterialTypical Shrinkage Characteristics
ABSRelatively stable shrinkage
PPHigher shrinkage due to crystallinity
PAHigher moisture sensitivity
POMHigh crystallinity and predictable shrinkage
Glass-filled NylonDirectional shrinkage caused by fiber orientation

Flow Characteristics: Material viscosity affects gate size, runner design, injection pressure, and filling distance. High-flow materials fill complex geometries easier and require lower injection pressure. High-viscosity materials may require optimized mold design and may increase processing difficulty.

Cooling Requirements: Different materials require different cooling strategies based on crystallinity, thermal conductivity, wall thickness, and mold temperature requirements. Poor cooling design may result in warpage, internal stress, and long cycle times.

2.3 Why Does Material Choice Affect Cycle Time and Manufacturing Cost?

Material cost is only one part of the total manufacturing equation. Many buyers compare plastics by asking “How much does this resin cost per kilogram?” However, professional manufacturers evaluate total manufacturing cost (TCO).

Industry insight: The cheapest material is often not the lowest-cost solution. A cheaper resin may increase cost if it causes longer drying requirements, higher rejection rates, more difficult processing, or shorter mold life. A slightly more expensive resin can sometimes reduce the total cost of ownership.

3. How Are Injection Molding Materials Classified?

Injection molding materials are generally classified according to their performance level, application requirements, and cost structure. This classification helps engineers quickly identify suitable material families before comparing specific resin grades.

3.1 Commodity Plastics

Commodity plastics are widely used polymers that provide low material cost, easy processing, high availability, and good chemical resistance. They are typically selected for products where extreme mechanical performance is not required. Common commodity plastics include PP (Polypropylene), PE (Polyethylene), and PS (Polystyrene).

  • Advantages: Excellent cost efficiency, high production availability, simple processing, good chemical resistance, and short molding cycles.
  • Limitations: Lower mechanical strength, lower temperature resistance, lower dimensional stability, and limited structural applications.

3.2 Engineering Plastics

Engineering plastics are designed for applications requiring improved mechanical strength, heat resistance, dimensional stability, wear resistance, and long-term reliability. Common engineering plastics include ABS, PC, PA6, PA66, POM, PBT, PMMA, and TPU.

  • Advantages: Best balance between performance, processing difficulty, and cost.
  • Typical applications: Automotive components, electronic housings, industrial equipment, medical devices, and precision mechanical parts.

3.3 High-Performance Engineering Plastics

High-performance polymers are designed for extreme environments. They provide exceptional temperature resistance, chemical stability, mechanical durability, and long-term reliability. Common materials include PPS, PEEK, PEI, and LCP.

  • Advantages: Exceptional performance in extreme conditions.
  • When to use: These materials are usually selected when failure is unacceptable. Typical applications include aerospace components, semiconductor equipment, medical implants, high-temperature electrical parts, and chemical processing equipment.

Engineering insight: High-performance plastics are not selected because they are “better.” They are selected because standard materials cannot meet the operating requirements. Using an expensive polymer unnecessarily can increase product cost without improving product value. The correct approach is: select the lowest-cost material that satisfies all functional requirements.

4. Injection Molding Material Comparison Table

No single plastic material provides the best combination of strength, cost, heat resistance, chemical resistance, and processing efficiency. Material selection requires understanding trade-offs.

MaterialStrengthImpact ResistanceHeat ResistanceChemical ResistanceTransparencyShrinkageCostTypical Applications
ABSMedium-HighGoodMediumMediumNoLow-MediumLowHousings, electronics, consumer products
PPMediumGoodMediumExcellentLimitedHighLowContainers, automotive parts, living hinges
PELow-MediumExcellentLow-MediumExcellentLimitedHighLowPackaging, tanks, chemical containers
PCHighExcellentHighMediumExcellentLowMedium-HighSafety covers, electronics, automotive
PA6HighGoodMedium-HighGoodNoMediumMediumGears, mechanical parts
PA66Very HighGoodHighGoodNoMediumMediumAutomotive, industrial components
POMHighMediumMediumExcellentNoMediumMediumPrecision gears, bearings
PMMAMediumLowMediumMediumExcellentLowMediumOptical covers, displays
PBTHighMediumHighExcellentNoLow-MediumMediumElectrical connectors
TPUMediumExcellentMediumGoodPossibleMediumMediumSeals, flexible parts
PPSVery HighMediumVery HighExcellentNoLowHighAutomotive, electronics
PEEKExtremely HighExcellentExtremely HighExcellentNoLowVery HighAerospace, medical, semiconductor

5. ABS – Acrylonitrile Butadiene Styrene

ABS is one of the most widely used engineering plastics because it provides a balanced combination of strength, impact resistance, surface appearance, processing stability, and cost efficiency. It is commonly considered one of the first material choices for general-purpose injection molded parts.

Key Properties: ABS combines three polymer components – Acrylonitrile (chemical resistance, heat resistance, surface hardness), Butadiene (impact resistance, toughness, low-temperature performance), and Styrene (rigidity, processability, surface finish).

PropertyTypical Value
Density1.04 g/cm³
Tensile Strength40–50 MPa
Flexural Modulus1800–2500 MPa
HDT80–100°C
Water Absorption0.2–0.5%
Shrinkage0.4–0.7%
Recommended Wall Thickness1.5–4 mm
Melt Temperature220–260°C
Mold Temperature40–80°C
Drying80°C, 2–4 hours

Advantages: Excellent surface appearance (smooth finishes, painting, plating, texturing), good balance between strength and cost, and easy injection molding processing (stable flow, good dimensional consistency, wide processing window).

Limitations: Limited heat resistance (not suitable for extremely high-temperature applications), and moderate chemical resistance (may be affected by strong solvents and certain chemicals).

Common Applications: Laptop housings, device covers, automotive interior panels, appliance control panels, equipment covers, toys, tools, and accessories.

Mold Design Considerations: Draft angle 0.5°-1.5°; supports edge gates, pin gates, and hot runners; gate location should minimize weld lines and visible defects; supports SPI finishes, texture patterns, and painted surfaces.

6. PP – Polypropylene

PP is one of the most widely used thermoplastics in the world because it provides an excellent balance between low material cost, chemical resistance, lightweight structure, fatigue resistance, and processing efficiency. It is especially valuable for products requiring living hinges, high-volume manufacturing, chemical resistance, low density, and moisture resistance.

PropertyTypical Value
Density0.90–0.91 g/cm³
Tensile Strength25–40 MPa
Flexural Modulus1000–1600 MPa
HDT80–110°C
Water Absorption<0.1%
Shrinkage0.8–2.0%
Recommended Wall Thickness1–5 mm
Melt Temperature200–250°C
Mold Temperature20–80°C
DryingUsually not required

Advantages: Excellent cost efficiency (low resin price, fast molding cycle, low processing difficulty), outstanding moisture resistance (stable dimensions in humid environments, no drying requirement in many applications), and excellent fatigue resistance (ability to withstand repeated bending – ideal for living hinges, snap-fit components, flexible lids).

Limitations: Lower mechanical strength compared with engineering plastics (lower tensile strength, rigidity, and heat resistance), higher shrinkage (0.8-2.0% affecting mold compensation and dimensional accuracy), and poor bonding/painting performance (low surface energy requiring surface treatment).

Common Applications: Battery cases, interior components, fluid tanks, containers, caps, bottles, storage boxes, disposable medical components, chemical tanks, and fittings.

7. PC – Polycarbonate

PC is a high-performance engineering plastic known for exceptional impact resistance, high transparency, good dimensional stability, and high temperature resistance. It is often selected when standard plastics cannot provide sufficient durability.

PropertyTypical Value
Density1.20 g/cm³
Tensile Strength60–70 MPa
Flexural Modulus2200–2500 MPa
HDT125–140°C
Water Absorption0.15–0.35%
Shrinkage0.5–0.7%
Recommended Wall Thickness1–5 mm
Melt Temperature280–320°C
Mold Temperature80–120°C
Drying120°C, 3–5 hours

Advantages: Extremely high impact strength (commonly used where failure could create safety risks), excellent transparency (optical clarity and light transmission), good heat resistance (maintains performance under higher temperatures compared with ABS and PP), and flame resistance availability (UL94 rated grades).

Limitations: Higher material cost (more expensive than PP and ABS), sensitivity to chemicals (may be affected by certain solvents and strong alkaline chemicals), and moisture sensitivity (requires drying before molding – incorrect drying can cause silver streaks, reduced strength, and surface defects).

Common Applications: Headlamp lenses, protective covers, safety shields, transparent components, and high-strength transparent parts.

Submit your product requirements for a free material selection consultation. Our engineering team will evaluate mechanical requirements, environmental conditions, certification needs, and cost targets to recommend the optimal material for your application.Request a Free Material Consultation →

8. PA6 and PA66 – Nylon

PA6 (Nylon 6) and PA66 (Nylon 66) are engineering plastics widely used for mechanical components because of their high strength, wear resistance, toughness, and fatigue performance. They are commonly used as metal replacement materials.

8.1 PA6 – Nylon 6

PropertyTypical Value
Shrinkage0.5–1.5%
Melt Temperature240–280°C
Mold Temperature60–100°C
Drying80°C, 4–8 hours

Advantages: High mechanical strength, excellent wear resistance, good impact resistance, and cost lower than many high-performance plastics. Suitable for structural parts, moving components, and impact loads.

Limitations: Moisture sensitivity (water absorption affects dimensions and mechanical properties), and lower dimensional stability compared with POM.

8.2 PA66 – Nylon 66

PropertyTypical Value
Shrinkage1.0–2.0%
Melt Temperature260–300°C
Mold Temperature70–120°C
DryingRequired

Advantages over PA6: Higher strength, higher temperature resistance, and better performance in demanding engineering applications.

8.3 PA6 vs PA66 Comparison

PropertyPA6PA66
StrengthHighHigher
Heat ResistanceMediumHigher
ProcessingEasierMore demanding
CostLowerHigher
Moisture AbsorptionHighHigh
Industrial UseCommonHeavy-duty

Common Applications: Gears, bearings, bushings, engine components, electrical connectors, structural brackets, and mechanical parts.

9. POM – Polyoxymethylene (Acetal)

POM, also known as Acetal, is a high-performance engineering plastic recognized for low friction, excellent dimensional stability, wear resistance, and precision performance. It is ideal for mechanical components requiring tight tolerances.

PropertyTypical Value
Shrinkage1.5–2.5%
Melt Temperature190–230°C
Mold Temperature80–120°C
DryingUsually not required

Advantages: Low friction (ideal for gears, bearings, and sliding components), excellent dimensional accuracy (lower moisture absorption than Nylon), wear resistance, and good chemical resistance for industrial environments.

Limitations: Limited impact resistance compared with PC and Nylon, and difficult bonding/painting due to low surface energy.

Common Applications: Gears, bearings, precision parts, fuel components, sliding components, and mechanical parts.

10. PMMA – Polymethyl Methacrylate (Acrylic)

PMMA, also known as Acrylic, is a transparent engineering plastic widely used as a glass alternative. It provides excellent transparency, UV resistance, good appearance, and scratch resistance.

PropertyTypical Value
Shrinkage0.4–0.8%
Melt Temperature220–260°C
Mold Temperature50–80°C
Drying80°C

Advantages: Optical performance (high light transmission, excellent clarity), weather resistance (performs well outdoors), and good appearance.

Limitations: Lower impact resistance compared with PC (more brittle, easier to crack), and stress cracking risk requiring careful design.

Common Applications: Lenses and covers, display panels, decorative parts, signage, lighting covers, and transparent panels.

11. PBT – Polybutylene Terephthalate

PBT is an engineering thermoplastic known for excellent dimensional stability, high electrical insulation performance, chemical resistance, heat resistance, and fast crystallization characteristics. It is widely used in automotive and electrical applications where reliability and precision are critical.

PropertyTypical Value
Density1.30–1.40 g/cm³
Tensile Strength50–70 MPa
Flexural Modulus2000–3000 MPa
HDT120–180°C
Water Absorption0.1–0.3%
Shrinkage1.0–2.0%
Melt Temperature240–270°C
Mold Temperature60–100°C
Drying120°C, 3–5 hours

Advantages: Excellent for electrical components (high insulation resistance, stable electrical properties, good arc resistance), good heat resistance, and suitable for glass fiber reinforcement (higher stiffness, reduced shrinkage, improved dimensional accuracy).

Limitations: Lower impact resistance compared with PC and PA, and requires proper drying (moisture can cause surface defects and reduced mechanical properties).

Common Applications: Electrical connectors, sensors, switch components, precision housings, and heat-resistant components.

12. TPU – Thermoplastic Polyurethane

TPU is a flexible engineering material that combines rubber-like elasticity, abrasion resistance, chemical resistance, and impact absorption. Unlike rigid plastics, TPU is selected when products require flexibility and durability.

PropertyTypical Value
Density1.10–1.25 g/cm³
Tensile Strength20–50 MPa
Elongation300–600%
HardnessShore A 60–95
Shrinkage0.5–1.5%
Melt Temperature180–230°C
Mold Temperature20–50°C
Drying80–100°C, 2–4 hours

Advantages: Excellent elasticity (can repeatedly deform and recover), outstanding wear resistance (performs well under repeated friction), and wide hardness range (Shore A 60-80 soft flexible parts, Shore D 40-70 semi-rigid applications).

Limitations: More difficult processing than ABS or PP (requires moisture control and optimized processing parameters), and higher cost than PP and ABS.

Common Applications: Protective cases, seals and vibration parts, flexible components, wheels, pads, gaskets, and medical flexible components.

13. PPS – Polyphenylene Sulfide

PPS is a high-performance engineering plastic designed for demanding applications requiring high temperature resistance, chemical stability, dimensional accuracy, and flame resistance. It is commonly used as a replacement for metals and ceramics in advanced applications.

PropertyTypical Value
Density1.35–1.60 g/cm³
Tensile Strength70–100 MPa
Flexural Modulus3000–10000 MPa
HDT220°C+
Water Absorption<0.1%
Shrinkage0.3–1.0%
Melt Temperature300–340°C
Mold Temperature120–180°C
Drying120°C

Advantages: Exceptional thermal performance (maintains mechanical properties at high temperatures), excellent chemical resistance (resists fuels, solvents, acids, and industrial chemicals), excellent dimensional stability (low moisture absorption, low shrinkage), and flame resistance (UL94 V-0 capability).

Limitations: High material cost (significantly more expensive than common engineering plastics), and processing requirements (high mold temperature, accurate process control).

Common Applications: Sensors, electrical components, connectors, high-temperature parts, and chemical-resistant components.

14. PEEK – Polyether Ether Ketone

PEEK is one of the highest-performance thermoplastics available. It is selected when products require extreme temperature resistance, chemical stability, high mechanical strength, and long service life. PEEK is often considered a metal replacement material in advanced industries.

PropertyTypical Value
Density1.30–1.40 g/cm³
Tensile Strength90–110 MPa
Flexural Modulus3500–4500 MPa
HDT250°C+
Water Absorption0.1–0.5%
Shrinkage1.0–2.0%
Melt Temperature360–400°C
Mold Temperature160–200°C
Drying150°C, 3–6 hours

Advantages: Exceptional temperature resistance (maintains performance under continuous high temperature, thermal cycling, and extreme environments), outstanding chemical resistance (resists acids, solvents, and radiation exposure), excellent mechanical strength (high stiffness, fatigue resistance, wear performance), and metal replacement capability (lower weight, corrosion resistance, easier integration).

Limitations: Very high material cost (one of the most expensive injection molding plastics), and difficult processing (requires high-temperature equipment, specialized tooling, and experienced molding engineers).

Common Applications: Aerospace lightweight structural parts, surgical components, semiconductor chemical-resistant parts, and high-performance bearings, seals, and sliding components.

15. Which Material Is Best for Different Applications?

Material selection should always begin with product requirements rather than material preference.

Product RequirementRecommended MaterialsReason
Low-cost consumer productsPP, ABSCost efficiency
High-impact housingPC, PC/ABSImpact resistance
Precision gearsPOM, PAWear resistance
Electrical connectorsPBT, PPSElectrical stability
Transparent coversPC, PMMAOptical performance
Flexible sealsTPUElasticity
High-temperature partsPPS, PEEKThermal resistance
Chemical containersPP, PE, PPSChemical resistance
Medical componentsPC, PEEK, PPSUCompliance options
Outdoor productsASA, PC, PMMAUV resistance

Engineering insight: Experienced engineers often select materials by asking “What failure mode are we trying to prevent?” This approach prevents over-engineering and reduces unnecessary material cost. For example: cracking → higher impact materials; wear → POM, PA, PEEK; heat deformation → PPS, PEEK; chemical attack → PP, PPS, PEEK; moisture change → POM, PBT.

16. Material Certifications and Regulatory Standards

Material selection is often affected by industry regulations. A technically suitable plastic may not be acceptable if certification requirements are not met.

StandardApplication
FDAFood contact materials
RoHSElectronic products
REACHChemical compliance
UL94Flame resistance
ISO 10993Medical applications
USP Class VIMedical plastics
IATF 16949Automotive supply chain

17. Common Material Selection Mistakes

  • Choosing materials only by price: A cheaper material may not satisfy strength, temperature, or chemical requirements.
  • Ignoring moisture absorption: Using Nylon without considering humidity effects can cause dimensional changes and assembly issues.
  • Ignoring UV exposure: Outdoor products require UV stabilizers and weather resistance.
  • Selecting prototype materials for production: 3D printed prototype materials may not represent final injection molded material properties.
  • Ignoring mold design requirements: Different materials require different gate designs, cooling strategies, and shrinkage calculations.

18. Frequently Asked Questions

Which injection molding plastic is the strongest?
There is no single strongest plastic. Highest temperature: PEEK; highest impact: PC; highest wear resistance: PEEK/POM; highest stiffness: reinforced PPS/PEEK.

ABS vs PC: Which material is better?
ABS offers lower cost, easier processing, and good appearance. PC offers higher impact resistance and higher temperature resistance. Choose based on application requirements.

PP vs PE: What are the differences?
PP offers better stiffness and heat resistance. PE offers better impact resistance and chemical resistance.

PA6 vs PA66: Which should I choose?
PA66 provides higher strength and higher temperature resistance. PA6 provides easier processing and lower cost.

POM vs Nylon: Which offers better wear resistance?
Both perform well. POM advantages: lower friction, better dimensional stability. Nylon advantages: higher toughness, better impact resistance.

Which plastics require drying before injection molding?
Common moisture-sensitive materials: PA, PC, PBT, TPU, PEEK. Materials such as PP and POM usually require less drying.

19. Conclusion

The best injection molding material is not the strongest material, the cheapest material, or the most advanced material. It is the material that provides the right balance between mechanical performance, environmental resistance, manufacturing feasibility, regulatory compliance, and total lifecycle cost.

Successful product development requires engineers to evaluate materials from both a product perspective and a manufacturing perspective. By understanding plastic classifications, material properties, processing requirements, mold design implications, and cost factors, companies can reduce development risks, improve production efficiency, and create reliable products that perform consistently throughout their service life.

A well-selected material does not only improve the product – it improves the entire manufacturing strategy.

Need Help Selecting the Right Injection Molding Material?

Submit your product requirements for a free material selection consultation. Our engineering team will evaluate mechanical requirements, environmental conditions, certification needs, and cost targets to recommend the optimal material for your application.Request a Free Material Consultation →

Turnaround within 48 hours. No obligation.

Disclaimer: This guide provides general technical information based on industry standards and engineering best practices. Actual results depend on specific materials, equipment, and production conditions. Always validate with trials and consult qualified engineers for project-specific decisions.

滚动至顶部