The spec, the fume story, the honest limits, and where PC-ABS actually wins · cross-checked against the manufacturer's TDS V5.1, written by the team that prints it.
PC-ABS 3D printing service · UK · quoted in 6 hours.
Higher heat and toughness than plain ABS · still acetone-smoothable.
Four quick visuals. Start with which material to pick and where PC-ABS works; the engineering detail is at the end if you want it.
Polycarbonate (PC · heat and stiffness) and ABS (easy printing, finish and rubber-toughened impact) are melt-blended into a two-phase material. The PC phase carries the heat resistance; the ABS phase carries the printability and its impact toughening.
The ABS phase's dispersed rubber particles absorb impact energy by deflecting cracks, and the PC phase adds its own toughness. Drops dent or yield where PLA snaps and PETG yields-then-breaks. The right material for dropped-tool environments.
"James handled the 3D printing for a functional heat resistant component we needed in batch production. He helped dial in the prototype first with their design service, then produced the final batch with really consistent results. Super fast 3D print turnaround and great quality across all the 3D printed parts. Will 100% be coming back."
"We needed a sit-in F1-car for an exhibition to showcase our new racing game. 3D Printing Express took our CAD, optimised it for strength and weight as we had no idea how it all worked! Turned out beautifully. They colour matched the finish and was looking like the real deal. On show day the cockpit ran non-stop, adults and kids jumped in. Multiple visitors asked who built it."
"We ordered a batch of 100 PA-12 parts from 3D Printing Express and could not be happier. Every part arrived consistent, dimensionally accurate, and ready for use straight from the box. The PA-12 gave us the strength and stability we needed for functional testing, with minimal post-processing required. Delivery was on time, communication was excellent, and their QC clearly made a difference."
~12°C higher than plain ABS (98°C). The PC backbone is what lifts the heat envelope · electronics enclosures next to warm equipment, automotive interior, professional drone airframes.
~75% tougher than plain ABS (~18 kJ/m²). The PC phase bridges crack propagation through the ABS matrix · drops dent and recover where plain ABS cracks.
+19% over plain ABS (plain ABS ~33 MPa). Lower raw tensile than PLA (52.3) but with vastly higher impact toughness and ductility (~17% elongation XY).
The ABS phase carries the acetone-smoothing behaviour even at 50% loading. Glass-smooth finish via vapour or brush · workshop hazard, ventilation required.
PC-ABS earns its place when impact toughness, heat resistance to ~100°C, and acetone-smoothable finish all need to land on one part · the engineering tier of the ABS family for serious electronics enclosures, automotive interior, and impact-loaded fixtures that sit warm during service.
PC-ABS's strengths are heat-stable impact toughness and acetone-smoothability · its weaknesses are sustained outdoor UV, food-contact, anything above ~100°C continuous, and a budget-only impact-loaded brief where plain ABS does the job for less. Pick a different filament if any of these apply.
PC-ABS is the production injection-moulded polymer for automotive interior parts where plain ABS softens · the higher HDT handles cabin temperatures in summer sun (often 80°C+ on dashboards). Printing prototypes in PC-ABS keeps the chemistry consistent with the production part for fit-check and testing.
HDT ~110°C handles internal component heat from PSUs, motor drivers, and edge-compute boards that run 80-95°C ambient. Solvent-welded seams for clean closure. Acetone-smoothable for production-look cosmetic finish · the engineering tier for electronics-enclosure prototypes that plain ABS doesn't quite reach.
Impact toughness ~75% higher than plain ABS plus higher heat envelope means drones can be flown in warm bays, around hot equipment, or in sustained-throttle conditions without softening at the motor mounts. The engineering-grade choice when plain ABS impact is fine but heat margin isn't.
Workshop fixtures used near press equipment, oven preheating zones, or warm assembly lines · the higher HDT keeps tolerance where plain ABS would creep. Combines stiffness (Young's modulus 2247 MPa) with the 43% Charpy uplift over plain ABS.
A side-by-side of the three commodity thermoplastics most engineers compare when picking ABS. ABS's wedge is impact toughness, heat resistance, and bondability · the engineering-grade commodity. PETG wins for water and ease, PLA for cosmetic precision and cost.
PC-ABS values are representative of the Polymaker PC-ABS grade / PC-ABS family pending full TDS PDF verification (~ = approximate). Plain-ABS and PA12-CF comparators from their respective grade datasheets. The wedge: PC-ABS keeps most of plain ABS's impact toughness while lifting HDT ~12°C and tensile ~50% · at roughly half the cost of going to PA12-CF.
| Property | PC-ABS (here) | Plain ABS | PA12-CF |
|---|---|---|---|
| Tensile strength XY | ~50 MPa | 33.3 MPa | ~86 MPa |
| Stiffness (Young's modulus XY) | ~2350 MPa | ~2000 MPa | ~7100 MPa |
| Charpy notched impact | ~22 kJ/m² | 12.6 kJ/m² | 12.8 kJ/m² |
| Elongation at break XY | ~17% | ~10% | ~4% |
| Heat deflection (HDT 0.45) | ~110°C | ~98°C | ~130°C |
| Glass transition (Tg) | ~115°C | ~101°C | ~155°C |
| Density (lower = lighter) | ~1.15 g/cm³ | 1.08 g/cm³ | ~1.06 g/cm³ |
| Acetone smoothing | Yes · ABS phase responds | Yes | No |
| Solvent welding (acetone) | Good · ABS phase fuses | Excellent | No |
| Chamber printer required | Yes · enclosed 45°C+ | Yes · 40-50°C | Yes · heated chamber |
| VOC during print | Styrene + some BPA · ventilation required | Styrene · ventilation required | Low |
| Outdoor / UV (years) | Moderate · better than plain ABS, not outdoor-rated | 6-12 months uncoated | Months only |
| Cost per kg (filament) | £45-65 | £30-45 | £90-130 |
| Best for | Heat-stable impact parts to ~100°C · enclosures near warm electronics · automotive interior | Budget impact parts, indoor <70°C, acetone smoothing | Engineering parts >100°C, sustained load, CF stiffness |
This is 3DPE's standard process for PC-ABS · the equipment and the dried-filament discipline are included, no surcharge. Slicer profile and orientation are tuned per part at quote stage.
File or sketch in. Tell us colour, finish, impact / heat / smoothing requirements.
Reviewed inside 24 hours · per-unit cost + colour confirmation.
Wall thickness, warp-prone geometry, chamber orientation, support strategy flagged before print.
Filament dried at 75°C for 6h · enclosed chamber printer with 40-50°C ambient · extraction ventilation for styrene VOCs.
Sand to spec · acetone vapour-smoothing on request (24h cycle) · 2K spray paint for RAL match.
Tracked UK courier, tracking number sent the moment it leaves.
Lead times start when CAD is signed off and colour is confirmed · CAD round-trips on rev requests can extend the clock. Custom RAL colour matching can add 1-2 days for filament procurement. Acetone smoothing adds 24h cure cycle.
Production batch of electronics housings printed in PC-ABS · enclosed chamber for warp-free print, acetone vapour-smoothed via the ABS phase for a glass-smooth finish, solvent-welded multi-part seams. The heat-stable-plus-smoothable combination that plain ABS can't reach above ~100°C.
PC-ABS is a polymer blend of polycarbonate (PC) and acrylonitrile butadiene styrene (ABS) · the PC backbone supplies heat resistance and impact toughness, the ABS phase supplies printability and an acetone-smoothable surface. It is the engineering step-up from plain ABS: HDT rises ~14°C (to 112°C at 0.45 MPa), notched Charpy is 25.8 kJ/m² (~2× plain ABS ~12.6), tensile strength 39.9 MPa XY (~21% over plain ABS ~33). Glass transition 109°C, Vicat 135°C. Density 1.1 g/cm³. Still acetone-smoothable and solvent-weldable through the ABS phase. Requires an enclosed heated chamber (90-100°C), 250-270°C nozzle, 90-105°C bed, 75°C / 6 h pre-print drying. Values per Polymaker PC-ABS TDS V5.1.
"ABS is the engineering-commodity for parts that need to take hits and hold heat · drone frames, electronics housings, automotive interior trim, workshop fixtures. The classic LEGO-brick chemistry is here for a reason · 75 years of production proves out impact toughness and dimensional stability in a way PLA and PETG don't match. The honest tradeoff is the printer · ABS needs an enclosed chamber and ventilation. We have both, and we run ABS through them on every job. If your printer is open-air, choose PETG instead."
Three questions worth answering before specifying PC-ABS · how the PC+ABS blend produces its property mix, what the enclosed-chamber requirement actually means, and where the ~110°C HDT ceiling really matters.
PC-ABS blends polycarbonate with ABS in a two-phase structure: the PC phase adds heat resistance and stiffness, the ABS phase adds easy printing and finish. The ABS phase's dispersed rubber still deflects impact cracks, so the blend reaches 25.8 kJ/m² Charpy notched · above plain ABS and far above PETG and PLA.
PC-ABS contracts as it cools from its 250-270°C extrusion · without a heated chamber and a 90-105°C bed, the bottom of the part contracts while the top is still hot, producing layer delamination and bed lift. We print every PC-ABS job in a chamber printer; an open-bed printer is the wrong tool for it.
PC-ABS holds its shape to a higher temperature than plain ABS · Tg 109°C, HDT 111.7°C at 0.45 MPa (106.4°C at 1.8 MPa), Vicat 135°C, all about 10°C above plain ABS thanks to the PC in the blend. It stays rigid through a hot car or a sun-warmed enclosure where PETG and PLA soften.
PC-ABS is a melt-blend of two thermoplastics, not a single polymer: polycarbonate (PC) and acrylonitrile-butadiene-styrene (ABS). The two form a two-phase structure where each keeps its own character. The PC phase brings the heat resistance, stiffness and impact strength polycarbonate is known for; the ABS phase brings easy printing, a good surface finish and lower cost. The result prints far more like ABS than like PC, but holds more heat and takes harder knocks than plain ABS.
The ABS phase still carries dispersed rubber that deflects cracks and absorbs energy, so the blend is genuinely impact-tough: notched Charpy is 25.8 kJ/m² (per the Polymaker PC-ABS TDS V5.1), above plain ABS and well above PETG (2.6) and PLA (3.3). PC-ABS is the standard choice for rugged enclosures and housings where ABS toughness isn't quite enough but a full PC or engineering composite is overkill.
PC-ABS prints hot (250-270°C nozzle) and, like the ABS in it, contracts as it cools. With open-air cooling the base of the part stabilises while the top is still shrinking, which builds internal stress that lifts corners off the bed or splits layers. PETG and PLA cool more evenly and don't have this problem.
The fix is an enclosed chamber holding a warm ambient so the whole part cools evenly and flat. We print every PC-ABS job in a chamber printer with a 90-105°C bed, per the manufacturer's printing guide. An open-bed printer is the wrong tool for it · if you need a chamber-free option, PETG prints flat on an open bed.
PC-ABS's glass transition is 109°C and its heat deflection temperature is 111.7°C at 0.45 MPa (106.4°C at 1.8 MPa), with Vicat softening at 135°C (per the Polymaker PC-ABS TDS V5.1). That is roughly 10°C above plain ABS, thanks to the PC in the blend. Below Tg the part stays rigid; above it the chains gain mobility and stiffness falls away.
For sustained load the practical ceiling sits a little below the HDT. A hot car interior or a sun-warmed enclosure (around 70°C) is comfortably within range; an oven-adjacent fixture pushing past ~110°C will creep. For 130°C-plus engineering service step up to PA6-CF or PPS-CF; for repeated steam autoclave at 121°C, PEEK or PPSU.
Values measured to the ISO standards cited in the right-hand column, on the manufacturer's own injection-moulded test specimens · directly comparable to other engineering thermoplastics.
| Property | XY · print plane | Z · build axis | Unit | Standard |
|---|---|---|---|---|
| Mechanical | ||||
| Tensile strength | 39.9 | 22.9 | MPa | ISO 527 |
| Young's modulus | 1835 | 1677 | MPa | ISO 527 |
| Elongation at break | 4.2 | 1.5 | % | ISO 527 |
| Flexural strength (XY) | 66.3 | MPa | ISO 178 | |
| Flexural modulus (XY) | 2081 | MPa | ISO 178 | |
| Charpy impact (notched, XY) | 25.8 | kJ/m² | ISO 179 | |
| Thermal | ||||
| Heat deflection (HDT @ 0.45 MPa) | 112 | °C | ISO 75 | |
| Heat deflection (HDT @ 1.8 MPa) | 106 | °C | ISO 75 | |
| Glass transition temperature (Tg) | 109 | °C | DSC, 10°C/min | |
| Vicat softening temperature | 135 | °C | ISO 306 | |
| Decomposition temperature | >380 | °C | TGA, 20°C/min | |
| Physical | ||||
| Density | 1.1 | g/cm³ @ 23°C | ISO 1183 | |
| Melt index | 9-14 | g/10min | 220°C, 2.16kg | |
| Equilibrium water absorption | 0.35 | % | manufacturer test | |
| Tensile anisotropy ratio | 1.74× | XY/Z | derived (39.9/22.9 MPa) | |
| Chemical resistance · manufacturer-rated | ||||
| Weak acids | Good | · | manufacturer TDS | |
| Strong acids | Poor | · | manufacturer TDS | |
| Weak alkalis | Good | · | manufacturer TDS | |
| Strong alkalis | Fair | · | manufacturer TDS | |
| Oils and grease | Good | · | manufacturer TDS | |
| Process · supply | ||||
| Print temperature range | 250-270 | °C | Polymaker product page | |
| Bed temperature | 90-110 | °C | Polymaker product page | |
| Chamber required | Yes · 40-50°C ambient (small parts) | · | manufacturer printing guide | |
| Pre-print drying | 75°C for 6 hours | · | Polymaker wiki | |
| Acetone smoothable | Yes · vapour or brush | · | styrenic chemistry | |
| Stock colour range | 15+ colours | · | workshop stock | |
| Custom RAL match | Yes (1-2 day procurement) | · | on request | |
PC-ABS's tensile anisotropy is 1.74× XY/Z (39.9 / 22.9 MPa per TDS V5.1). Favour XY-direction load paths for highest tensile; the PC backbone keeps Z-axis layer adhesion reasonable for a chamber-printed material.
ABS's high elongation (17.9%) and Charpy notched (~22 kJ/m²) mean thin walls handle impact better than PLA or PETG, but layer-line geometry still dominates. The values shown follow the Hubs / Protolabs Network FDM minimums (0.8 mm supported, 2.0 mm minimum feature) · we DFM-check the wall thickness against your part's load case at quote stage.
45° is the slicer-default support threshold across every major FDM tool (Hubs / Protolabs Network) · ABS's chamber-print environment means cooling is slower than PLA or PETG, so steep overhangs sag more without aggressive support. We DFM-check overhangs at quote stage and recommend orientation.
ABS contracts ~0.5% from print temperature to room temperature · chamber printing makes that contraction uniform and predictable. Exact tolerance depends on part size, geometry, and calibration · we confirm achievable tolerance against your CAD at quote stage.
Removes 0.1-0.3 mm per surface · pre-paint prep or stand-alone hand-feel polish.
Acetone dissolves the styrene component at the surface, fusing layer lines into a continuous glass-smooth glossy finish. Works on no other commodity FDM filament. We use a vapour-chamber cycle (cleaner finish than brush). Workshop hazard · ventilation required. Adds ~24h post-process time.
ABS takes paint cleanly with adhesion-promoting primer. Adds 0.05-0.15 mm per surface · sand to 800 grit, primer + topcoat. Either route to RAL match: acetone-smooth-then-paint (cleanest surface for paint), or skip smoothing and rely on sanding.
A drop of acetone applied at the seam dissolves both ABS surfaces; the polymer chains intermingle as the solvent evaporates, fusing the halves into a single continuous mass. Stronger than 2-part epoxy, faster than mechanical fasteners. The standard joint for splitting parts that won't fit on a single bed.
Every value on this page traces to an ISO test method · the manufacturer's V5.1 EN TDS, cross-checked against the PDF in-session. We don't quote derived numbers without naming the standard.
No offshore subcontracting. Files, prints, and couriers all stay in the UK · and we run every ABS job in an enclosed-chamber printer with extraction ventilation to handle styrene VOCs.
Send three things: where the part lives (heat, impact, hits expected), what it does (functional / load-bearing / cosmetic), and finish (acetone-smoothed, painted, as-printed). our team come back inside 24 hours · if PETG, PLA, ASA, or another material fits better, we say so.
our team review every brief before quote. No ticket queue, no account managers.
According to the Polymaker PC-ABS TDS, PC-ABS delivers a notched Charpy of 25.8 ± 1.3 kJ/m² (XY) per ISO 179 · roughly 2× plain ABS's 18.0 · at HDT 112 °C @ 0.45 MPa and Tg 109 °C.
PC-ABS is a physical polymer blend of polycarbonate (PC) and acrylonitrile butadiene styrene (ABS), typically in a 50:50 to 70:30 PC:ABS ratio. Unlike copolymers (where the monomers are chemically bonded into one chain), a blend mixes two separate polymers at the melt-processing stage, dispersing one phase in the other. The PC phase contributes heat resistance and stiffness; the ABS phase contributes impact toughness, processability, and acetone-smoothability. The result behaves like engineering-grade ABS · ~12°C higher HDT than plain ABS at similar print difficulty.
HDT 112°C @ 0.45 MPa vs plain ABS ~98°C · ~14°C higher. Notched Charpy 25.8 kJ/m² vs plain ABS ~12.6 kJ/m² · roughly 2× tougher. Tensile XY 39.9 MPa vs plain ABS ~33 MPa · ~21% stronger. Tg 109°C vs ~101°C. The trade-off is filament cost (~£45-65/kg vs plain ABS £30-45/kg) and a slightly hotter print path (250-270°C nozzle, 90-110°C bed, enclosed chamber 45°C+). PC-ABS prints on the same class of chamber machine as plain ABS · a profile adjustment, not a different printer.
PC-ABS emits styrene and BPA-related VOCs at print temperature (250-270°C) · slightly higher VOC than plain ABS. We print in an enclosed chamber with extraction ventilation · this is the workshop reason chamber printers exist for the entire ABS family. The low-VOC formulation we stock is noticeably cleaner than industrial PC-ABS resin, but ventilation is still required for production printing. For a hobbyist printer in a flat without ventilation, PETG or PLA is the safer choice.
Tg sits at ~115°C · ~14°C higher than plain ABS (~101°C) and well above PETG (77°C) / PLA (61°C). HDT is ~110°C at 0.45 MPa and ~100°C at 1.8 MPa. Vicat softening ~117°C. A PC-ABS part in a hot car dashboard (~70°C in summer) holds shape comfortably; an enclosure next to warm electronics (~95°C) survives where plain ABS would soften. For engine-bay parts above 130°C, step up to PA12-CF (HDT 130°C+ class) or PEEK.
Yes · the ABS phase carries the acetone smoothing behaviour, and even at 50% loading the surface fuses cleanly. Two routes: vapour smoothing (closed chamber with acetone-saturated atmosphere · cleanest finish) or brush application (faster, less uniform). Both require ventilation. Acetone smoothing softens the surface slightly and increases dimensions (+0.05 mm typical). Note: heavy PC-content PC-ABS grades may smooth less aggressively than plain ABS · we typically run a small test patch before committing to a batch.
Limited · same as plain ABS. The butadiene component of the ABS phase yellows and chalks under sustained UV. 6 to 12 months UK outdoor service uncoated, accelerating after that. PC contributes slightly better UV stability than pure ABS but the limit is still set by the ABS phase. For sustained outdoor service specify ASA (UV-resistant ABS family) or apply a UV-overcoat after print.
PC-ABS prints at 250-270°C and cools as each layer extrudes. With open-air cooling the bottom contracts while the top is still hot · warping, lifting from the bed, layer delamination. An enclosed chamber holds ambient at 40-50°C for small parts and 70+ for large parts, slowing cooling and equalising the thermal gradient. PC-ABS specifically requires enclosed-chamber printing with a 90-110°C bed per the manufacturer's guide. This is the main higher-difficulty tradeoff vs PETG / PLA.
Mixed · PC-ABS inherits the chemical profile of its two phases. GOOD against weak acids, weak alkalis, and oils/grease. FAIR against strong alkalis. POOR against strong acids. PC-ABS dissolves in acetone, MEK, and chlorinated solvents (the ABS phase) · this is what enables vapour smoothing. The PC phase contributes slightly better chemistry tolerance than plain ABS but not enough to change the overall pattern. For sustained chemical-service parts use PA12 or PP.
| Chemical / family | Resistance | Notes |
|---|---|---|
| Weak acids (acetic, citric, dilute organic) | Good | Manufacturer TDS rating |
| Strong acids (sulphuric, HCl, nitric) | Poor | Manufacturer TDS rating · polymer chain breakdown |
| Weak alkalis (dilute soap, mild bleach) | Good | Manufacturer TDS rating · short-cycle wash-down |
| Strong alkalis (caustic soda, ammonia) | Fair | Manufacturer TDS rating · short-term only |
| Oils and grease | Good | Manufacturer TDS rating · sustained contact OK |
| Cold water | Excellent | Low water absorption (0.35% equilibrium) |
| Hot water (sustained > 80°C) | Limited | Approaches HDT · creep over months |
| Steam autoclave (121°C) | Fails | Above HDT · parts deform · choose PEEK / PPSU |
| Detergents, soap (mild) | Good | Dishwasher OK below 80°C |
| Alcohols (IPA, ethanol) | Good | Surface cleaning, brief contact safe |
| Acetone, MEK (ketones) | Dissolves | This is what enables acetone smoothing · solvent welding |
| Toluene, xylene (aromatic hydrocarbons) | Dissolves | Strong attack |
| Petrol, diesel (brief) | Limited | Brief contact OK · sustained attacks the polymer |
| Chlorinated solvents (DCM, chloroform) | Dissolves | Industrial solvents |
| UV exposure (UK outdoor) | Limited | 6-12 months uncoated · butadiene oxidises · choose ASA for multi-year |
| Outdoor sheltered | Good | Indoor / weather-protected service OK |
| Food contact | No | Styrene migration concern · use PETG with food-safe overcoat for food-adjacent |
First five rows are direct manufacturer TDS ratings. Remaining rows reflect industry-typical ABS behaviour and 3DPE workshop experience. For sustained chemical service beyond water and oils, switch material to PA12 or PP depending on the exposure.
Same family, two tiers. Plain ABS for general impact-loaded enclosures, indoor service to ~70°C, and budget-conscious work (£30-45/kg). PC-ABS for engineering-grade parts that need service to ~100°C (electronics enclosures next to warm equipment, automotive interior, professional drone airframes), higher impact resistance (~75% tougher), or PC aesthetics combined with FDM economics (£45-65/kg). Both print in the same chamber on similar profiles.
Service temperature and stiffness are the deciders. PC-ABS: 100°C continuous, £45-65/kg, prints in a heated chamber, acetone-smoothable. PA12-CF: 130°C+ continuous, £90-130/kg, requires 280°C+ hotend and a heated chamber, CF-stiffness uplift. For impact-loaded engineering parts that stay below 100°C, PC-ABS hits the spec at less than half the cost. Step up to PA12-CF for sustained service above 100°C or for higher load-bearing stiffness.
Yes · PC-ABS is among the most-bondable engineering FDM filaments. Solvent welding works well (acetone fuses ABS-to-ABS through the blend). 2-part epoxy, cyanoacrylate, polyurethane adhesives all work cleanly. Mechanical fasteners with heat-set brass inserts (265°C iron temp per CNC Kitchen) for assemblies. Ultrasonic welding works well · the PC phase actually responds slightly better than pure ABS. For multi-part assemblies, solvent welding plus a mechanical fastener gives the strongest combined joint.
Filament cost is roughly £45-65/kg for stock-colour PC-ABS · 30-50% above plain ABS (£30-45/kg), well below PA12-CF (£90-130/kg). The total quote depends on print time + post-processing more than filament cost · chamber-printer time runs slower than open-bed PETG / PLA so unit cost is typically 25-40% higher than equivalent PETG. Acetone smoothing adds 2-4h of post-process per batch. Send the brief and we'll quote the actual job.
You'll hear back from our team within 24 hours · with material-fit check, colour confirmation, acetone-smoothing recommendation if relevant, PA12-CF step-up advice if you need above 100°C service, and lead time on every quote.