Selecting the right thermoplastic is one of the most critical decisions in custom extrusion. This guide helps procurement managers and engineers weigh the most common materials for performance, compliance, and cost.
Before choosing a material, weigh these essentials against your application:
Best for: windows & doors, construction, electrical conduit, medical tubing
Advantages: Excellent weatherability, flame retardant, cost-effective.
Limitations: Lower impact strength at cold temperatures; environmental concerns with certain formulations.
Typical applications: Window profiles, pipe, wire insulation, medical devices.
Best for: automotive, appliances, consumer products, protective housings
Advantages: High impact resistance, good rigidity, attractive surface finish.
Limitations: Poor UV resistance (needs additives or painting); moderate chemical resistance.
Typical applications: Automotive trim, appliance housings, protective gear, musical instruments.
Best for: packaging, agricultural tubing, chemical storage, toys
Advantages: Excellent chemical resistance, flexibility, low moisture absorption.
Limitations: Lower strength and stiffness than engineering plastics.
Typical applications: Agricultural tubing, chemical containers, food packaging, playground equipment.
Best for: automotive, medical devices, lab equipment, living hinges
Advantages: Excellent chemical resistance, fatigue resistance, living-hinge capability.
Limitations: Brittle at low temperatures; susceptible to UV degradation.
Typical applications: Automotive interior components, medical devices, lab equipment, storage containers.
Best for: safety equipment, lighting, medical devices, electronics
Advantages: Exceptional impact resistance, optical clarity, heat resistance.
Limitations: Susceptible to stress cracking with certain chemicals; higher cost.
Typical applications: Safety glasses, medical device housings, lighting diffusers, electronic components.
Best for: seals, gaskets, grips, medical tubing, automotive seals
Advantages: Rubber-like elasticity, good abrasion resistance, recyclable.
Limitations: Generally higher cost; limited high-temperature performance.
Typical applications: Medical tubing, automotive seals, tool grips, sporting goods.
Primary choice: PVC (weatherable formulation) · Watch UV stability, impact resistance, thermal expansion. Alt: ASA or fiberglass-reinforced composites.
Primary choice: Polyethylene (LDPE or HDPE) · Chemical resistance to fertilizers, UV stabilization, flexibility. Alt: PVC for rigid fittings.
Primary choice: ABS for housings, PP for interior components · Heat resistance, impact strength, surface finish. Alt: PC/ABS blends for higher heat.
Primary choice: ABS, PP, TPE/TPU · Temperature cycling, resistance to oils and cleaners, dimensional stability.
Primary choice: PVC, polycarbonate, polypropylene · FDA compliance, resistance to sterilants, clarity. Alt: specialty biocompatible grades.
Many thermoplastics accept post-industrial or post-consumer recycled content. PCR (post-consumer) typically runs 10–30% without significant property loss; PIR (post-industrial) often 20–50% depending on application. Certifications such as UL Ecologo, Cradle to Cradle, and LEED credits may be available.
UV stabilizers protect against sunlight degradation; flame retardants meet UL94 ratings for electrical applications; antioxidants extend service life in demanding environments; colorants deliver consistent, UV-stable color; and antimicrobials serve medical and food-contact applications.
| Material | Relative cost | Key attributes | Best value for |
|---|---|---|---|
| PVC | Low | Weatherability, flame retardancy | Construction, electrical |
| Polyethylene | Low–Medium | Chemical resistance, flexibility | Packaging, agriculture |
| Polypropylene | Medium | Chemical & fatigue resistance | Automotive, medical |
| ABS | Medium | Impact strength, surface finish | Appliances, consumer goods |
| Polycarbonate | High | Impact resistance, clarity | Safety, medical, lighting |
| TPE/TPU | High | Elasticity, abrasion resistance | Seals, medical tubing |
At Custom Profiles, material consultation is part of our design process. We analyze your requirements and environmental conditions, recommend two to three material options with pros and cons for each, build test samples to validate performance, help balance performance against budget, and make sure materials meet the certifications your application needs.
The right material choice lets your part perform reliably for its full service life — while keeping cost in check.
Custom Profiles has over 30 years of experience in thermoplastic extrusion across multiple industries. Contact our engineering team for a material selection consultation.