Material Alternatives for Plastic Injection Molding

Material Alternatives for Plastic Injection Molding

During material supply shortages, consider these resin substitutes for ABS, PC, PP, and other commonly molded thermoplastics. Navigating supply chain issues is a constant challenge, especially in times of material shortages. At Konlida Precision Technology, we have compiled a list of substitution options that can serve well as replacements. Choosing which ones to use depends on material properties and the intended function of your parts.

We stock hundreds of engineering-grade thermoplastics and accept customer-supplied resins. For up‑to‑date availability, contact our team. For detailed data sheets, visit our Materials Comparison Guide.

ASA (Acrylonitrile Styrene Acrylate)

ASA copolymers have excellent resistance to UV irradiation, moisture, heat, and cracking – probably the best weathering resistance of all acrylonitrile elastomers. Mechanical properties are similar to ABS (good chemical resistance and high impact strength). Superior weathering resistance makes ASA more suitable for outdoor applications than ABS.

Applications: Automotive mirror housings, radiator grilles, building construction, appliance products, electrical & electronics, sports goods.

Key advantage: Outstanding UV stability without painting.

More ASA material data →

COC (Cyclic Olefin Copolymer)

COC is a shatter‑resistant substitute for glass in optical lenses and films, particularly in medical and electronic applications (diagnostic tubes, touch screens ITO film, light guides, reflection films). Excellent biocompatibility, chemical resistance, and superior water vapour barrier make it ideal for pharmaceutical packaging and medical diagnostics.

Properties: high light transmissivity (>90%), low birefringence, high refractive index, extremely low water absorption (<0.01%), high rigidity and hardness.

Common uses: Primary packaging for drugs, medical disposables, optical components.

Medical applications of COC →

PCT (Polycyclohexylenedimethylene Terephthalate)

High‑performance semi‑crystalline polyester. Mechanical properties (30% glass fibre) similar to PET 30% GF, but with superior hydrolysis and heat resistance. Melting point: 285°C vs PET 245°C. Low moisture absorption, excellent electrical properties, good chemical resistance.

Applications: Plug connectors, relays, switches, distribution boxes – can be drop‑in replacement for PBT where higher temperature resistance is required (automotive, electronics).

PEEK / PAEK (Polyether Ether Ketone)

Semi‑crystalline high‑performance thermoplastics with exceptional thermal stability, chemical resistance, and mechanical properties over a wide temperature range. Low creep, good sliding/wear properties, continuous service temperature >250°C. Excellent resistance to hot water, hydrolysis, and many chemicals. Often used as metal replacement in demanding applications (high‑speed rotors, bearing shells, aircraft components).

Considerations: Poor UV resistance – not for prolonged outdoor use without protection. Very high cost.

View PEEK technical data →

PEI (Polyetherimide – Ultem)

Amber‑to‑transparent high‑performance amorphous thermoplastic. Outstanding thermal, mechanical, and chemical properties. Continuous service temperature up to 371°C (short‑term 538°C). Excellent creep resistance, inherently flame retardant (UL94 V‑0), high radiation resistance, low outgassing. Service temperature range: -270°C to +300°C.

Applications: Aerospace, transportation, electronics, medical devices (probe housings, digital card printer frames, coil springs).

Limitations: Expensive, high processing temperatures, not for use above Tg without annealing.

PEI material details →

PESU (Polyethersulfone)

High toughness, strength, and hydrolytic stability. Heat deflection temperature 204°C. Inherently flame retardant, good chemical resistance, excellent electrical properties, transparent. End‑use temperature range: -40°C to 204°C.

Applications: Electronics, membranes, healthcare, automotive, food‑contact. Higher temperature resistance than PSU, but sensitive to polar solvents (ketones, chlorinated) and UV.

PMMA (Polymethyl Methacrylate – Acrylic)

Amorphous, transparent thermoplastic with high Tg (~125°C), good mechanical properties, excellent weatherability. Economical alternative to polycarbonate when high impact strength is not required. Lightweight, shatter‑resistant glass replacement. Impact‑modified grades offer up to 10× higher toughness while maintaining clarity (92% transmission).

Applications: Signs, optical fibres, tail lights, sanitary fixtures, architectural glazing.

PPA (Polyphthalamide)

Semi‑crystalline, melt‑processible polyamide (semi‑aromatic). Lower moisture absorption than aliphatic nylons (PA66/PA6), excellent dimensional stability, high strength and stiffness at elevated temperatures. Cost‑effective alternative to expensive aramids. Melting point of PA6T ~322°C.

Applications: Motor parts, fuel line connectors, coolant pumps, bushings, engine cover components, high‑voltage bushings, charge air coolers.

Automotive applications of PPA →

PPO (Polyphenylene Oxide)

High tensile and impact strength, resistant to steam, hot water, mineral and organic acids. Susceptible to stress cracking and thermal oxidation – therefore often blended with HIPS or PA (e.g., Noryl).

Applications: Pump parts, fan impellers, catalyst supports, plugs, insulators, household articles.

PPS (Polyphenylene Sulfide)

Semi‑crystalline engineering thermoplastic with high melting point (~285°C). Outstanding heat and chemical resistance, good dimensional stability, high tensile/flexural strength. Typically glass‑fibre or mineral filled. Excellent dielectric strength stable over wide temperature and frequency range.

Applications: Electrical/electronic parts (plugs, connectors, relays), automotive air intake systems, pump parts, bearings in corrosive environments. Also used for encapsulation and precision mechanical parts.

PPSU (Polyphenylsulfone)

Highest‑performing polysulfone – high toughness, high flexural/tensile strength, excellent hydrolytic stability, best chemical resistance among polysulfones. Resistant to aqueous mineral acids, bases, oxidizing agents and most solvents (avoid ketones/ethers).

Applications: Pipe fittings, battery containers, medical device parts, sterilizable healthcare products (autoclave resistant), aerospace interiors. Not for outdoor use (poor UV resistance).

Medical device sterilization applications →

PSU (Polysulfone)

Amorphous, transparent high‑performance thermoplastic. Excellent mechanical, electrical, and thermophysical properties. High tensile and impact strength (similar to PC), excellent chemical/hydrolytic stability. Resistant to steam and hot water. Low mold shrinkage allows tight tolerances.

Applications: Faucet components, coffee machine internals, medical devices, water treatment membranes, plumbing manifolds. Not recommended for outdoor use (poor UV resistance).

SPS (Syndiotactic Polystyrene)

Highlights of SPS include:

• Resistance to hydrolysis: Superior to polyester/polyamide resins, comparable to PPS.
• Chemical resistance: Resists corrosion by various acids, alkalis, automotive oils and antifreeze.
• Low specific gravity: One of the lowest among engineering plastics – reduces part weight and cost.
• Heat resistance: Long‑term 130°C, HDT 250°C, melting point 270°C – suitable for wave and reflow soldering.
• Electrical properties: Dissipation factor and dielectric constant similar to fluororesins; stable over wide frequency/temperature – ideal for high‑frequency components.
• Dimensional stability: Low anisotropic mold shrinkage; good dimensional performance vs. other glass‑reinforced crystalline resins.
• Processability: High flow (near LCP), easy molding, minimal thermal degradation, easy to grind – recyclable.

Applications: Electronic components for hybrid electric vehicles, surface mount chip parts, connectors, home appliances, lead‑free solder compatible.

SPS in consumer electronics →

Common Thermoplastics and Their Material Alternatives