When developing new products, choosing the right materials for prototype and replica parts directly affects testing accuracy, production efficiency, and cost control. This article will break down common materials, their performance comparisons, and selection strategies to help you make informed decisions.
1. Core Materials for Prototype & Replica Parts: Overview & Key Traits
Below is a detailed table of 7 widely used materials, including their core advantages, typical applications, and limitations—designed to let you quickly match materials to your needs.
| Material Name | Core Advantages | Typical Applications | Limitations |
| Polyurethane (PU) | High strength, good expandability; flexible/rigid options | Soft rubber parts, ABS/PC-like replicas | Lower heat resistance than high-temp materials |
| Silicone | Excellent elasticity, easy demolding | Elastic components (e.g., gaskets, soft grips) | Low mechanical strength; not for load-bearing parts |
| ABS | Balanced strength & toughness, easy processing | Structural prototypes (e.g., housings, frames) | Poor chemical resistance to strong solvents |
| PP (Polypropylene) | Good chemical stability, heat resistance (~100°C) | Food-contact parts, lightweight components | Low impact resistance at low temperatures |
| PC (Polycarbonate) | High transparency, strong impact resistance | Transparent parts (e.g., lenses, covers) | Prone to scratching; higher cost than acrylic |
| Acrylic (PMMA) | Superior transparency, easy polishing | Display prototypes (e.g., exhibition models) | Brittle; lower impact resistance than PC |
| High-Temperature Resistant Materials | Withstands >200°C; maintains performance in heat | Engine parts, high-temp tooling | Higher cost; complex processing |
2. How to Compare Materials for Specific Needs? (Contrast & Decision Guide)
Not sure whether to pick PC vs. Acrylic for a transparent part, or PU vs. Silicone for a flexible component? Use these side-by-side comparisons to resolve common dilemmas.
2.1 Transparent Prototype Parts: PC vs. Acrylic
| Comparison Factor | PC (Polycarbonate) | Acrylic (PMMA) |
| Transparency | ~90% (slight blue tint) | ~92% (clearer) |
| Impact Resistance | Excellent (unbreakable in most cases) | Poor (easily cracked) |
| Scratch Resistance | Low (needs coating) | Medium (better than PC) |
| Cost | Higher | Lower |
| Recommendation | For parts needing durability (e.g., safety covers) | For display-only parts (e.g., model showcases) |
2.2 Flexible Prototype Parts: PU vs. Silicone
If your project requires flexibility, ask: Do I need strength or extreme elasticity?
- PU: Ideal for parts that need both flexibility and structural support (e.g., soft rubber grips for tools). It can mimic the hardness of ABS or PC, making it versatile for functional testing.
- Silicone: Better for parts that prioritize elasticity and heat resistance (e.g., seals for high-temp devices). However, its low mechanical strength means it’s not suitable for load-bearing roles.
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