PAI vs PPSU
Polymer · grade comparison
PAI and PPSU are both polymer grades, both high performance plastic. PAI is the stronger of the two: tensile strength 152 MPa (22 ksi) against 70 MPa (10.2 ksi) for PPSU, about 117% more. In exchange, PPSU is the more ductile: elongation 80% versus 15% for PAI. PPSU is lighter (1.29 g/cm³ vs 1.42 g/cm³ for PAI) and PAI is stiffer (4.5 GPa vs 2.3 GPa). On the shop floor, PPSU welds better (very good vs not recommended).
PAIChoose it when strength drives the design, or when the part sees heat.
PPSUChoose it when the part is bent, formed or impact-loaded, or when weight is the constraint.
PAI vs PPSU: propertiesHow to read these bars
- One bar per material. A full bar is the highest value among all polymer grades in the FabDigit library; each bar is drawn as a share of that.
- The better value (by the usual engineering direction) is in bold. Rows with no direction — density, thermal conductivity — have no bold.
- Values are typical room-temperature figures for the condition named on each card.
- Confirm against the certified mill or resin datasheet before design release.
How to read these bars
- One bar per material. A full bar is the highest value among all polymer grades in the FabDigit library; each bar is drawn as a share of that.
- The better value (by the usual engineering direction) is in bold. Rows with no direction — density, thermal conductivity — have no bold.
- Values are typical room-temperature figures for the condition named on each card.
- Confirm against the certified mill or resin datasheet before design release.
Mechanical
Strength, stiffness, ductility and hardness at room temperature.
Elastic (Young's) Modulus
Shear Modulus
Poisson's Ratio
Tensile Strength (Ultimate)
Elongation at Break
Compressive Strength
Compressive Modulus
Flexural Strength
Flexural Modulus
Shear Strength
Izod Impact, Notched
Hardness, Shore D
Hardness, Rockwell M
Yield Strength (0.2% offset)
Fracture Toughness (K_IC)
Hardness, Rockwell R
Physical
Density and transition temperatures.
Density
Glass Transition (Tg)
Water Absorption (24 h)
Water Absorption (Saturation)
Refractive Index
Thermal
How each material carries heat and how hot it can run.
Thermal Conductivity
Specific Heat Capacity
Thermal Expansion (CTE, 20–100 °C)
Max Service Temperature (continuous)
Min Service Temperature
Heat Deflection Temp. @ 0.45 MPa
Heat Deflection Temp. @ 1.8 MPa
Limiting Oxygen Index
Max Service Temperature (short-term)
Vicat Softening Point (B50)
Electrical
Conductivity and insulation.
Electrical Resistivity
Dielectric Strength
Dielectric Constant (1 MHz)
Dissipation Factor (1 MHz)
Volume Resistivity
Surface Resistivity
Comparative Tracking Index (CTI)
Chemical & Environmental
Corrosion and environmental resistance (0–100 scores).
Corrosion Resistance
UV / Weathering Resistance
Manufacturability
FabDigit workshop ratings (0–100 scores) — how each material behaves on the machine.
Machinability
Weldability
Formability (cold)
Mold Shrinkage
Processing Melt Temperature (typ.)
Mold Temperature (typ.)
Melt Flow Rate
Same in both: Polishability 70 / 100
Sustainability
Primary-production footprint per kilogram.
Embodied Energy (primary production)
Embodied Carbon (primary production)
Embodied Water
Same in both: Typical Recycled Content 0%
Common Calculations
Ratios derived from the values above.
Specific Strength (UTS / density)
Specific Stiffness (E / density)
Same in both: Thermal Diffusivity 0.2 mm²/s · Thermal Shock Resistance Index 0
Strength versus weight
Yield strength against density for every polymer grade in the FabDigit library; the compared grades are highlighted. Up and left is stronger for its weight.
Manufacturing and finishing
| Capability | PAI | PPSU |
|---|---|---|
| Default condition | Unfilled (Electrical) | Medical Grade |
| Relative cost | $$$$$ Specialty | $$$$$ Specialty |
| Min. machined wall | 0.5 mm | 0.5 mm |
| Best machined surface | Ra 0.8 µm | Ra 0.8 µm |
Both are offered for CNC machining, Sheet metal and Injection molding. Both take the same 6 finishes: Chrome Plating (Plastic), EMI Shielding Coating, Painting, Soft Touch Coating, Spray Painting, UV Coating.
PAI vs PPSU — frequently asked
Is PAI stronger than PPSU?
Yes. PAI has a typical tensile strength of 152 MPa (22 ksi) against 70 MPa (10.2 ksi) for PPSU — about 117% more.
Which is cheaper, PAI or PPSU?
Both sit in the same relative cost tier ($$$$$, specialty); the part price will be decided by machining time, tolerance and quantity rather than by the material.
Which welds better, PAI or PPSU?
PPSU. Its weldability rates very good (70/100) against not recommended (10/100) for PAI.
Ready to make it?
Upload a CAD file and FabDigit prices the part in PAI and PPSU side by side — material, machining time, tolerance and finish in one quote. Certified material data ships with the order on request.
Typical handbook values for the conditions named above, normalised for comparison. Hardness on non-Brinell scales is converted approximately for charting only. Request certified data with your order for design-critical properties.