Choosing the right plastic material is one of the most important steps in designing a housing. Whether you’re building a small remote, a rugged outdoor device, or a sleek consumer gadget, the choice of material affects everything—strength, heat resistance, surface finish, and even color. That’s why experienced Electronic Injection Molding engineers and skilled Mold Maker teams always start with the right resin.
This article explores the best materials for plastic housings used in Electronic Injection Molding. With tips from seasoned Mold Maker experts, we’ll look at how to balance durability, moldability, and cost.
Why Material Selection Matters
In Electronic Injection Molding, the material is not just a shell—it’s part of the product’s strength and function. A brittle or warped housing can cause failures. A poorly chosen resin might not survive heat or chemicals. Every Mold Maker knows that a great mold is only as good as the plastic it shapes.
Material choice influences:
- Mechanical strength
- Heat and flame resistance
- UV and chemical durability
- Surface finish and color options
- Warpage and shrinkage control
- Ease of molding and cycle time
Getting this choice right helps ensure your product performs well, looks good, and lasts long.
ABS – Acrylonitrile Butadiene Styrene
ABS is one of the most widely used plastics in Electronic Injection Molding. It offers a balance of toughness, stiffness, and good surface finish. It’s also easy to mold, making it a top choice for consumer housings.
Advantages:
- High impact resistance
- Smooth surface for painting or plating
- Good dimensional stability
- Easy to process in molds
Applications:
Used in TV remotes, keyboards, routers, and control panels.
Mold Maker Tip: Keep wall thickness consistent to avoid sink marks. ABS also benefits from venting in areas with deep ribs or bosses.
PC – Polycarbonate
Polycarbonate is strong, clear (if needed), and heat-resistant. It’s often used where strength and safety are critical. Many Electronic Injection Molding products that face rough handling use PC.
Advantages:
- High impact resistance
- Heat resistance
- Flame retardant grades available
- Good optical clarity (for light guides or windows)
Applications:
Used in phone covers, industrial controls, safety devices.
Mold Maker Tip: PC is sensitive to moisture. Dry the resin before molding to avoid bubbles. Molds should have strong gates and polished surfaces to prevent drag marks.
PC/ABS Blend – The Best of Both
PC/ABS blends combine the toughness of PC with the easy processability of ABS. Many Electronic Injection Molding teams choose this when parts need strength, a clean look, and UL flame ratings.
Advantages:
- Good balance of strength and appearance
- Easier to mold than pure PC
- Flame retardant options available
- Stable for overmolding or two-shot designs
Applications:
Used in laptop cases, automotive electronics, and smart devices.
Mold Maker Tip: Use vented cores and smooth ejector pins. This blend needs a strong mold to handle its viscosity and cooling rate.
PP – Polypropylene
Polypropylene is a lightweight, chemical-resistant plastic often used for low-cost or water-safe housings. While it’s not as stiff as ABS, its flexibility makes it suitable for snap-fit designs in Electronic Injection Molding.
Advantages:
- Chemical and water resistance
- Tough and fatigue-resistant
- Very low cost
- Good for living hinges
Applications:
Used in battery compartments, simple enclosures, and outdoor gear.
Mold Maker Tip: PP shrinks more than other plastics. Design draft angles carefully, and check gate design to prevent flow lines and warpage.
PA – Nylon (Polyamide)
Nylon is strong and heat-resistant. It’s used in structural housings or components that must endure mechanical stress. It’s often reinforced with glass fiber for extra strength.
Advantages:
- High mechanical strength
- Good heat resistance
- Wear-resistant
- Reinforced grades available
Applications:
Used in connectors, gears, automotive electronics, and tool housings.
Mold Maker Tip: Nylon absorbs moisture. Store and dry it carefully. Use strong ejector systems, especially for glass-filled grades, which are abrasive on mold steel.
PBT – Polybutylene Terephthalate
PBT is often used for precision parts that need electrical insulation and high heat resistance. It’s common in plug connectors and sensor housings.
Advantages:
- Dimensional stability
- Good electrical properties
- Heat and flame resistance
- Smooth surface finish
Applications:
Used in electronic modules, switches, and automotive sensors.
Mold Maker Tip: PBT flows well and fills thin areas easily. However, it can flash if venting isn’t perfect. Always use fine-tuned parting lines and vent gaps.
Special Considerations for Electronic Injection Molding
When selecting a material for Electronic Injection Molding, think beyond strength and appearance. The plastic must also:
- Support tight tolerances for PCB mounting
- Handle heat near processors or power circuits
- Pass flammability standards (UL 94V-0)
- Accept textures, logos, or laser etching
A professional Mold Maker understands how each plastic flows, shrinks, and cools. They help match the design and resin to achieve smooth, repeatable production.
Flame Retardant Grades
Electronics often require flame ratings for safety. Many materials come in UL 94V-0 grades, meaning they self-extinguish after ignition. These grades are critical in Electronic Injection Molding for consumer, medical, and industrial products.
Mold Maker Tip: Flame-retardant resins can be more brittle. Add ribs or supports to avoid cracks. Also, they can leave build-up in molds—cleaning must be regular.
Bioplastics and Eco-Friendly Options
More companies now look for sustainable options. Bioplastics and recycled materials are entering the Electronic Injection Molding space. Some ABS and PC grades now contain recycled content or bio-based feedstock.
Advantages:
- Lower carbon footprint
- Some are compostable or recyclable
- Good for green branding
Challenges:
- May not meet mechanical or flame standards
- Require mold tuning
Mold Maker Tip: Work closely with your Mold Maker when using eco-resins. Flow rates and cooling profiles often differ from standard plastics.
How a Good Mold Maker Helps You Choose
Choosing material isn’t just the job of designers. A smart Mold Maker plays a key role. They bring:
- Real-world experience with resins
- Knowledge of mold steel vs. plastic compatibility
- Insight into warpage and venting behavior
- Help with mold surface finish (polish vs. texture)
Early input from a Mold Maker helps avoid costly mistakes. They know how a resin behaves—not just in theory, but in real mold cavities.
The right plastic makes a big difference in the success of your product. A good housing must be strong, attractive, and easy to mold. In Electronic Injection Molding, the material must also resist heat, protect electronics, and meet standards.
To choose the best material:
- Match performance needs with plastic properties
- Balance cost, moldability, and looks
- Consider safety ratings and environmental goals
- Always work with a trusted Mold Maker
With the right material and the right team, you’ll get perfect parts—every cycle.