Best Plastic Materials for Custom Machine Equipment Housings

Choosing the right plastic material for custom vacuum formed housings is a critical step in designing durable, lightweight, and cost-effective enclosures for industrial equipment. Different working environments and application demands require tailored material performance—from impact resistance and UV protection to ease of forming and long-term stability.

This guide helps manufacturers and procurement teams identify which plastics best fit their equipment housing needs, based on real-world use cases and proven engineering considerations.

Top 6 Plastic Materials Commonly Used for Equipment Housings

When it comes to vacuum forming large or mid-sized enclosures, six materials are most commonly used due to their balanced performance and affordability:

• ABS (Acrylonitrile Butadiene Styrene)
  Strong, rigid, and impact-resistant. ABS is the go-to material for most machinery housings due to its easy formability and excellent dimensional stability.
• HIPS (High Impact Polystyrene)
  More affordable than ABS, HIPS is suitable for indoor applications where high impact or UV resistance is not critical.
• PC (Polycarbonate)
  Offers outstanding impact resistance and transparency. Ideal for high-end housings or protective covers that require visual clarity and high strength.
• HDPE (High-Density Polyethylene)
  Known for chemical resistance and low moisture absorption, making it suitable for wet or corrosive environments.
• PVC (Polyvinyl Chloride)
  Offers excellent fire resistance and decent mechanical strength, often used in electrical or HVAC equipment housings.
• ASA (Acrylic Styrene Acrylonitrile)
  Highly UV-resistant and color-stable. Best suited for outdoor housings or sun-exposed equipment.

Key Considerations When Selecting a Material

Selecting the right plastic goes beyond appearance or price. Consider the following performance factors for optimal results:

• Impact Resistance
  For rugged machinery or equipment exposed to frequent handling, ABS and PC are excellent choices due to their shock-absorbing capabilities.
• UV and Weather Resistance
  For outdoor equipment, ASA and UV-stabilized ABS provide longer service life with minimal discoloration or cracking.
• Chemical Resistance
  For environments with oil, grease, or mild solvents, HDPE and PVC offer superior chemical resilience.

Comparing ABS, PC, and HIPS for Vacuum Formed Parts

Let’s take a closer look at how the three most commonly used plastics perform:

Conclusion:

• Choose ABS for balanced strength and cost
• Go with PC if clarity and high impact resistance are required
• Use HIPS for simple, low-cost indoor enclosures

Material Selection by Application Scenario

Each working environment places different demands on housing materials:

• Indoor Factory Equipment
  HIPS or ABS is typically sufficient, balancing cost and toughness.
• Outdoor Machinery (e.g. kiosks, charging stations)
  Use ASA or UV-resistant ABS for weather exposure.
• Heavy-Duty or Mobile Equipment
  Polycarbonate is preferred for maximum impact resistance and temperature stability.
• Moist or Chemical-Prone Environments
  HDPE and PVC resist moisture absorption and corrosion, making them ideal for cleaning equipment or lab devices.

Mistakes to Avoid in Material Selection

Poor material choice can lead to part failure, discoloration, or warping. Avoid these common issues:

• Overlooking UV exposure
  Indoor-use plastics like HIPS degrade rapidly outdoors without UV stabilizers.
• Using low-impact plastics in mobile units
  Equipment in transit or mounted on moving bases needs high toughness.
• Ignoring forming temperature compatibility
  Not all plastics are equally suitable for thermoforming. Polycarbonate, for instance, requires tight temperature control and may increase cycle time.

Final Thoughts: Match Material to Design and Budget

Material selection for custom vacuum formed housings should be a balance of performance, budget, and manufacturability. It's important to discuss your project’s environmental conditions, structural needs, and expected lifespan with your vacuum forming partner.

A professional manufacturer will help guide the decision between options like ABS, PC, or HDPE—often combining them with multilayer techniques or surface coatings to meet exact requirements.