PC-ABS Blend

Physical properties

Laser processing

During combustion, ABS emits styrene monomers (possible carcinogen), acrylonitrile (toxic), and butadiene. The polycarbonate fraction adds small amounts of bisphenol-A (BPA) vapours. Extraction with HEPA+activated carbon is mandatory. PC-ABS fumes have a characteristic acrid, slightly sweet odour: this is a warning sign of inadequate extraction.

CO₂: PC-ABS cuts well with CO2 laser. The cut edge has a slightly different colour compared to ABS-only: less orange, more grey-yellow. Requires 10–15% more power than pure ABS of same thickness due to the polycarbonate fraction. Engraving gives good contrast (light grey mark on the typically dark or black surface typical of PC-ABS). Minimal melting.

Diode: Cuttable with 5W+ diode laser on dark-coloured PC-ABS only. The surface must be dark (black or dark grey); white or transparent versions are impossible with a diode. Multiple passes required for >2mm. The polycarbonate component provides marginal thermal stability improvement over pure ABS.

Fiber: Not applicable.

CNC / milling processing

Excellent CNC machinability, combining the best of both polymers. The ABS fraction prevents the PC from becoming 'gummy' when heated; the PC fraction prevents the ABS from becoming too brittle. Single-flute bits, moderate speeds (18,000–24,000 RPM), and aggressive chip loads (0.05–0.10mm/tooth). Compressed air cooling prevents melting. Better chip ejection than pure PC.

3D printing

Plotter and thermoforming

Post-processing

Sanding: PC-ABS sands acceptably. Not as polishable as pure PC, but less greasy than pure ABS. Use grits 240 → 400 → 600 → 1200. Wet sanding reduces heat. Flame polishing does not work on PC-ABS as the surface becomes opaque/matte rather than glossy.

Primer: mandatory. A specific primer for plastics is mandatory. Standard automotive spray primers for polyolefins do not bond. Recommended: plastic primer spray (solvent-based for ABS/PC blend) or adhesion promoter. Flame or plasma treatment improves adhesion but is rarely necessary for PC-ABS.

Gluing: Excellent with solvent-based adhesives (dichloromethane or MEK, but these require extreme extraction – dichloromethane is a Schedule 3 carcinogen). Epoxy and polyurethane adhesives are high-risk for delamination. The best practical adhesive for PC-ABS is cyanoacrylate (superglue), especially rubber-toughened or gel versions.

Seasoning: Store in a dry environment away from direct sunlight. PC-ABS absorbs less moisture than PA but can absorb up to 0.2% by weight in high humidity. Drying at 80°C for 2–4 hours before processing improves results.

Over time: Good mechanical stability over time, the best compromise between PC (impact resistance) and ABS (processability). Resistant to moderate UV exposure (better than ABS, worse than PC). Continuous moisture exposure weakens the ABS fraction; long-term outdoor use requires UV and moisture protection.

Common defects

• Warping in FDM printing — requires heated enclosure and heated bed
• Mixed fumes (styrene + phenol) during laser processing — ventilation more critical than with pure ABS
• Difficult structural bonding with standard solvents

Safety

Recommended PPE: mask_p2

Fumes from laser cutting are toxic (styrene, acrylonitrile, BPA traces). Never cut without extraction. PVC contamination risk: verify your supplier sells pure PC-ABS, not a PVC blend. Cutting PVC-coated 'PC-ABS' releases chlorine gas (lethal). Always burn a small sample and check for green flame before processing an unknown sheet.

Availability and formats

Commercial formats: filament 1.75mm, filament 2.85mm, granules, sheets

Related materials

Sources

• SABIC Cycoloy — Technical data sheet
• ISO 2580 + ISO 7391 (blend reference)