Material Selection for Extruded Strips: Key Considerations
When designing extruded plastic strips for industrial, commercial, or residential applications, material selection directly impacts performance, durability, and total cost of ownership. Polyethylene (PE), polyvinyl chloride (PVC), and acrylonitrile butadiene styrene (ABS) are three of the most commonly used thermoplastics in extrusion processes. Each offers distinct mechanical, thermal, and chemical properties that influence suitability for specific use cases. This comparison focuses on the practical differences between PE vs PVC vs ABS extrusion, emphasizing performance characteristics, processing requirements, and cost-effectiveness.
Mechanical and Physical Properties
Polyethylene (PE)
PE, particularly high-density polyethylene (HDPE), is valued for its high impact strength, excellent abrasion resistance, and flexibility. It exhibits low tensile strength compared to ABS and rigid PVC but performs well in low-stress, high-wear environments. PE has a low coefficient of friction, making it suitable for sliding applications. Its elongation at break ranges between 100–1000%, depending on grade, which supports use in flexible profiles. However, PE has limited stiffness and dimensional stability under load, restricting its use in structural components.
Polyvinyl Chloride (PVC)
PVC exists in two primary forms: rigid (PVC-U) and flexible (PVC-P). Rigid PVC is widely used in extruded strips due to its high tensile strength (5,000–8,000 psi), rigidity, and dimensional stability. It maintains shape under moderate loads and performs well in load-bearing applications such as window and door frames. Flexible PVC, plasticized with additives, offers improved flexibility and impact resistance but at the expense of strength and heat resistance. PVC’s density (1.3–1.45 g/cm³) is higher than PE, increasing weight and material costs per volume.
Acrylonitrile Butadiene Styrene (ABS)
ABS combines the rigidity of polystyrene with the toughness of polybutadiene rubber. It delivers high impact resistance, especially at low temperatures, and maintains structural integrity under mechanical stress. ABS has a tensile strength of 4,000–6,000 psi and a flexural modulus of 200,000–300,000 psi, making it suitable for high-stress applications like appliance trim, automotive parts, and electrical housings. However, ABS is more susceptible to UV degradation and requires additives for outdoor use.
Thermal and Chemical Resistance
Heat Resistance and Processing Temperatures
PE has a low melting point (120–140°C) and poor heat deflection temperature (HDT ~60–80°C), limiting its use in high-temperature environments. PVC-U has a higher HDT (65–85°C) and can be formulated to resist temperatures up to 100°C. ABS offers superior thermal stability with an HDT of 90–105°C, enabling use in applications exposed to elevated temperatures. During extrusion, PE requires lower processing temperatures (160–220°C), while PVC (160–190°C) and ABS (200–240°C) demand more precise temperature control due to thermal degradation risks.
Chemical and Environmental Stability
PE demonstrates excellent resistance to acids, bases, and alcohols but is vulnerable to UV radiation and oxidizing agents. PVC is highly resistant to oils, solvents, and many chemicals, making it ideal for chemical storage and industrial seals. However, it releases hydrochloric acid when thermally degraded, requiring proper ventilation during processing. ABS offers moderate chemical resistance but is attacked by acetone, chlorinated solvents, and strong acids. All three materials benefit from UV stabilizers and flame-retardant additives when used in outdoor or safety-critical applications.
Cost and Processing Efficiency
Material and Production Costs
PE is the most economical option, with raw material costs typically 20–30% lower than PVC and ABS. Its low processing temperatures reduce energy consumption, improving throughput. PVC is mid-range in cost but offers the best balance of performance and price for rigid structural applications. ABS is the most expensive, often 1.5–2 times the cost of PE, due to its complex copolymer structure and higher processing energy demands.
Extrusion Processability
PE extrudes smoothly with minimal die swell and excellent melt strength, enabling high-speed production of thin-walled profiles. PVC, especially rigid grades, requires careful formulation to prevent thermal degradation and ensure consistent melt flow. It also exhibits higher melt viscosity, necessitating specialized screw designs. ABS has good melt flow but is sensitive to moisture and requires thorough drying before processing. Post-extrusion, ABS and PVC benefit from vacuum calibration for dimensional accuracy, while PE may require more aggressive cooling due to slower crystallization rates.
Application-Specific Suitability
For refrigerator gaskets, flexible seals, and low-cost trims, refrigerator-grade plastic profiles made from PE or flexible PVC are optimal due to flexibility and moisture resistance. Rigid PVC dominates in window and door profiles for its weatherability and stiffness. ABS is preferred for high-impact, precision-molded components such as appliance handles, instrument housings, and automotive interior trims. For custom extrusion needs requiring material-specific expertise, Dalang’s extrusion services provide tailored solutions across all three materials.
Selecting between PE vs PVC vs ABS extrusion requires a detailed analysis of mechanical demands, environmental exposure, and lifecycle costs. Matching material properties to application requirements ensures optimal performance and cost efficiency. Dalang specializes in custom extrusion services for PVC, UPVC, ABS, PE, and other plastic materials, widely used in windows, doors, refrigerators, and various applications requiring precision plastic components.