PC/ABS (Polycarbonate + ABS Blend): Applications, Advantages & Injection Molding Guide

PC/ABS (Polycarbonate + ABS Blend): Applications, Advantages & Injection Molding Guide

PC/ABS is a blend of polycarbonate (PC) and acrylonitrile butadiene styrene (ABS), combining the toughness and heat resistance of PC with the ease of processing and cost-effectiveness of ABS. This thermoplastic alloy offers an ideal balance of mechanical performance, aesthetics, and manufacturability, making it popular in automotive, consumer electronics, and industrial equipment.

What Is PC/ABS?
PC/ABS materials offer enhanced impact resistance, dimensional stability, and heat resistance compared to ABS alone, while improving flow and processability over pure PC. The typical blend ratio is adjusted depending on the application—more PC increases thermal and impact performance, while more ABS improves processing ease.

Key Applications of PC/ABS
PC/ABS is used in a wide variety of applications where strength, finish, and durability are critical.

Automotive Industry
– Dashboards, trim panels, and bezels
– Air conditioning vent housings and console frames
– Pillar covers and interior fascia

Electronics & Appliances
– Laptop shells, printer housings, keyboard frames
– Battery cases, handheld device enclosures
– Audio and video equipment casings

Industrial Equipment
– Tool housings and power tool casings
– Office machine enclosures and business equipment parts

Medical Devices (non-implantable)
– Diagnostic housings and monitor casings
– Components that require both durability and visual appeal

Advantages of PC/ABS
– Excellent impact resistance at low and room temperatures
– Superior surface finish and dimensional stability
– Moderate heat resistance (higher than ABS alone)
– Easily painted, plated, welded, or bonded
– Good balance of stiffness and ductility
– Compatible with flame-retardant additives for electronic applications

Injection Molding Guidelines for PC/ABS
1. Drying Requirements
PC/ABS absorbs moisture, which can lead to surface defects and poor mechanical properties.
– Target moisture: < 0.04%
– Drying temperature: 90–110 °C
– Drying time: 2–4 hours in a desiccant dryer

2. Melt and Mold Temperatures
– Melt temperature: 230–300 °C depending on blend ratio and grade
– Mold temperature: 50–100 °C (higher for better surface finish and dimensional stability)

3. Injection Pressure & Speed
– Pressure: Medium to high, depending on part geometry
– Speed: Medium to high speed; avoid shear that can lead to yellowing or degradation

4. Runner and Gate Design
– Use fan, edge, or submarine gates with generous runner systems
– Avoid small gates on large parts to prevent poor fill and weld lines
– Hot runner systems are possible but require precise thermal control

Common Defects & Troubleshooting
– Burn marks: Reduce injection speed or temperature, improve venting
– Silver streaks: Dry material thoroughly and reduce moisture absorption
– Poor surface gloss: Increase mold temperature or use polished mold cavities
– Brittleness: May indicate overheating or poor drying

Final Thoughts
PC/ABS is a versatile thermoplastic blend offering the best of both worlds—strength and impact resistance from PC, with processing ease and cost advantages from ABS. It is ideal for manufacturers seeking performance, aesthetics, and reliable manufacturability.
From rugged electronics housings to automotive interiors, PC/ABS delivers a balance of design flexibility and technical performance.
Need help choosing the right PC/ABS blend or optimizing your molding setup? Contact our materials specialists for guidance tailored to your product needs.