Material selection is a critical decision in equipment design. Engineers often evaluate whether a component should be manufactured from plastic or metal based on performance requirements, cost, and environmental conditions.

While metal has traditionally been used for strength and durability, advances in engineering plastics have made plastic a viable alternative in many applications.

Understanding the trade-offs between plastic and metal helps engineers select the right material for each component.

Strength and Structural Performance

Metal is typically associated with high strength and rigidity, making it suitable for load-bearing applications.

However, modern plastics can provide sufficient strength for many applications while offering additional benefits such as flexibility and impact resistance.

Plastic components may perform well when:

• loads are moderate
• impact resistance is required
• some flexibility is beneficial

Metal is often preferred when:

• high structural loads are present
• minimal deflection is required
• extreme durability is needed

Weight Reduction

One of the most significant advantages of plastic is weight reduction.

Plastic components are substantially lighter than metal, which can improve:

• equipment efficiency
• ease of handling
• transportation costs

Weight reduction is especially valuable in applications such as agricultural equipment, mobile machinery, and infrastructure systems.

Corrosion and Environmental Resistance

Plastic materials offer excellent resistance to corrosion, moisture, and many chemicals.

Unlike metal, plastic does not rust or require coatings to prevent corrosion.

Plastic is often preferred in:

• outdoor environments
• high-moisture applications
• chemical exposure conditions

Metal components may require additional treatments such as coatings or plating to achieve similar resistance.

Manufacturing and Cost Considerations

Plastic extrusion can provide cost advantages, particularly for continuous profiles.

Benefits include:

• lower tooling costs compared to complex metal fabrication
• reduced secondary operations
• consistent production output

Metal components may require:

• machining
• welding
• finishing processes

These additional steps can increase overall production cost and lead time.

Design Flexibility

Plastic allows for greater design flexibility in certain applications.

Extrusion enables engineers to create:

• complex cross-sectional profiles
• integrated features
• continuous lengths

Metal fabrication may require assembling multiple parts to achieve similar functionality.

Thermal and Mechanical Limitations

Plastic does have limitations compared to metal.

Engineers must consider:

• temperature exposure
• long-term creep under load
• UV exposure (for outdoor use)

Metal may still be required in high-temperature or high-load environments.

Choosing the Right Material

Selecting between plastic and metal depends on:

• load requirements
• environmental conditions
• cost targets
• weight considerations
• manufacturability

In many cases, replacing metal with plastic can reduce cost and weight while maintaining performance.

Working with OEM Engineers

Lincoln Plastics works with OEM manufacturers to develop plastic components that replace or complement traditional metal parts.

Applications include:

• agricultural equipment
• industrial machinery
• infrastructure protection systems
• cord management products

If you're evaluating plastic versus metal for a component, our team can help review your design and material options.

Contact us today:
https://www.lincoln-plastics.com/contact-us

Engineer Education Series

Explore the full series:

Engineer Education Series #1:
Designing Plastic Extrusion Profiles – Key Engineering Considerations

Engineer Education Series #2:
Plastic Extrusion Tolerances – What Engineers Should Expect

Engineer Education Series #3:
Common Design Mistakes Engineers Make with Plastic Extrusion

Engineer Education Series #4:
How Plastic Extrusion Tooling Works

Engineer Education Series #5:
Plastic Extrusion vs Injection Molding – When to Use Each

Engineer Education Series #6: Plastic vs Metal Components in Equipment Design
Engineer Education Series #7: Designing Plastic Components for Outdoor Equipment
Engineer Education Series #8: Co-Extrusion vs Single Material Extrusion
Engineer Education Series #9: How Engineers Collaborate with Extrusion Manufacturers
Engineer Education Series #10: Material Selection for Extruded Plastic Parts

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