{"$schema":"nativecad-dfm-pack/1","id":"materials","title":"Materials — metals, plastics, wood and composites for any process","sector":"materials","version":"2026-09-03","summary":"Cross-sector material properties and selection facts: density, stiffness, strength, temperature limits and cost class for common CNC/molding/print/wood/composite materials, plus gauge tables, print-process matrices, galvanic and food-contact compatibility.","aliases":["material","aluminium","aluminum","steel","stainless","plastic","abs","nylon","polycarbonate","pla","petg","plywood","mdf","titanium","brass","copper","carbon fiber","composite"],"crossSector":true,"size":"standard","sources":[{"id":"matweb","title":"MatWeb Material Property Data","url":"https://www.matweb.com/","accessed":"2026-09-03"},{"id":"protolabs-materials","title":"Protolabs material comparison guide","url":"https://www.protolabs.com/resources/design-tips/material-selection/","accessed":"2026-09-03"},{"id":"xometry-materials","title":"Xometry material selection guide","url":"https://www.xometry.com/resources/materials/","accessed":"2026-09-03"},{"id":"astm-a36","title":"ASTM A36/A36M Carbon Structural Steel","url":"https://www.astm.org/a0036_a0036m-19.html","accessed":"2026-09-03"},{"id":"astm-a240","title":"ASTM A240/A240M Stainless Steel Plate","url":"https://www.astm.org/a0240_a0240m-23a.html","accessed":"2026-09-03"},{"id":"astm-b221","title":"ASTM B221 Aluminum Extruded Shapes","url":"https://www.astm.org/b0221-21.html","accessed":"2026-09-03"},{"id":"astm-b265","title":"ASTM B265 Titanium Strip/Sheet/Plate","url":"https://www.astm.org/b0265-20.html","accessed":"2026-09-03"},{"id":"formlabs-materials","title":"Formlabs SLA resin data sheets","url":"https://formlabs.com/materials/","accessed":"2026-09-03"},{"id":"hp-mjf-materials","title":"HP MJF PA12 material data sheet","url":"https://www.hp.com/us-en/printers/3d-printers/products/multi-jet-materials.html","accessed":"2026-09-03"},{"id":"ansys-galvanic","title":"Galvanic series in seawater reference","url":"https://www.copper.org/resources/properties/corrosion/galvanic.html","accessed":"2026-09-03"},{"id":"fda-usp-class-vi","title":"FDA 21 CFR 177 / USP Class VI reference","url":"https://www.fda.gov/food/packaging-food-contact-substances-fcs/food-contact-substances-fcs","accessed":"2026-09-03"},{"id":"engineering-toolbox-gauge","title":"Eng. ToolBox sheet gauge to mm","url":"https://www.engineeringtoolbox.com/steel-gauges-d_1636.html","accessed":"2026-09-03"},{"id":"sae-j403","title":"SAE J403 SAE Carbon Steel Compositions","url":"https://www.sae.org/standards/content/j403_201409/","accessed":"2026-09-03"}],"entries":[{"id":"al-6061-t6","kind":"material","tier":1,"title":"Aluminum 6061-T6","summary":"6061-T6: 2.70 g/cm3, E 69 GPa, yield 276 MPa, UTS 310 MPa, max temp 150C, cost 2/5. Best all-round CNC alloy — machines cleanly, anodizes, welds.","applies":["cnc machining","extrusion"],"value":{"table":[{"density":2.7,"E":69,"yield":276,"uts":310,"elongPct":12,"maxTempC":150,"costClass":2}]},"basis":"MatWeb 6061-T6 datasheet; the default general-engineering aluminum alloy","sources":["matweb"],"tags":["aluminum","aluminium","6061"],"check":{"process":"machining","rule":"min_wall_thickness"}},{"id":"al-7075-t6","kind":"material","tier":1,"title":"Aluminum 7075-T6","summary":"7075-T6: 2.81 g/cm3, E 71.7 GPa, yield 503 MPa, UTS 572 MPa, max temp 120C, cost 4/5. Highest-strength common aluminum; poor weldability.","applies":["aerospace bracket","high-strength fixture"],"value":{"table":[{"density":2.81,"E":71.7,"yield":503,"uts":572,"elongPct":11,"maxTempC":120,"costClass":4}]},"basis":"MatWeb 7075-T6 datasheet; aerospace-grade high-strength alloy","sources":["matweb"],"tags":["aluminum","aluminium","7075"]},{"id":"al-5052-h32","kind":"material","tier":1,"title":"Aluminum 5052-H32 (sheet)","summary":"5052-H32: 2.68 g/cm3, E 70.3 GPa, yield 193 MPa, UTS 228 MPa, max temp 150C, cost 2/5. The sheet-metal alloy — bends tighter than 6061.","applies":["sheet metal","enclosure"],"value":{"table":[{"density":2.68,"E":70.3,"yield":193,"uts":228,"elongPct":12,"maxTempC":150,"costClass":2}]},"basis":"MatWeb 5052-H32 datasheet; standard sheet-metal aluminum grade","sources":["matweb"],"tags":["aluminum","aluminium","5052"],"check":{"process":"sheet_metal","rule":"min_internal_corner_radius"}},{"id":"steel-1018","kind":"material","tier":1,"title":"Mild steel 1018 (low-carbon)","summary":"1018 CR: 7.87 g/cm3, E 200 GPa, yield 370 MPa, UTS 440 MPa, max temp 400C, cost 1/5. Cheapest general machining/weld steel; not hardenable.","applies":["cnc machining","weldment"],"value":{"table":[{"density":7.87,"E":200,"yield":370,"uts":440,"elongPct":15,"maxTempC":400,"costClass":1}]},"basis":"MatWeb 1018 cold-rolled datasheet; SAE J403 composition","sources":["matweb","sae-j403"],"tags":["steel","mild steel","1018"]},{"id":"steel-4140","kind":"material","tier":1,"title":"Alloy steel 4140 (Q&T)","summary":"4140 Q&T: 7.85 g/cm3, E 205 GPa, yield 655 MPa, UTS 1020 MPa, max temp 425C, cost 2/5. Through-hardenable chromoly; needs preheat to weld.","applies":["shaft","gear"],"value":{"table":[{"density":7.85,"E":205,"yield":655,"uts":1020,"elongPct":17,"maxTempC":425,"costClass":2}]},"basis":"MatWeb 4140 quenched-and-tempered datasheet","sources":["matweb"],"tags":["steel","alloy steel","4140"]},{"id":"ss-304","kind":"material","tier":1,"title":"Stainless steel 304","summary":"304: 8.00 g/cm3, E 193 GPa, yield 215 MPa, UTS 505 MPa, max temp 870C, cost 3/5. Non-magnetic, weldable — the default food-safe stainless.","applies":["food equipment","enclosure"],"value":{"table":[{"density":8,"E":193,"yield":215,"uts":505,"elongPct":40,"maxTempC":870,"costClass":3}]},"basis":"MatWeb 304 annealed datasheet; ASTM A240 composition","sources":["matweb","astm-a240"],"tags":["stainless","304","food safe"]},{"id":"ss-316","kind":"material","tier":1,"title":"Stainless steel 316","summary":"316: 8.00 g/cm3, E 193 GPa, yield 205 MPa, UTS 515 MPa, max temp 870C, cost 4/5. Mo-alloyed for pitting resistance — marine and medical grade.","applies":["marine hardware","medical device"],"value":{"table":[{"density":8,"E":193,"yield":205,"uts":515,"elongPct":40,"maxTempC":870,"costClass":4}]},"basis":"MatWeb 316 annealed datasheet; ASTM A240 composition","sources":["matweb","astm-a240"],"tags":["stainless","316","marine"]},{"id":"brass-c360","kind":"material","tier":1,"title":"Brass C360 (free-machining)","summary":"C360: 8.50 g/cm3, E 97 GPa, yield 310 MPa, UTS 385 MPa, max temp 200C, cost 3/5. The free-machining brass — best machinability of any alloy.","applies":["fitting","valve body"],"value":{"table":[{"density":8.5,"E":97,"yield":310,"uts":385,"elongPct":18,"maxTempC":200,"costClass":3}]},"basis":"MatWeb C36000 half-hard datasheet","sources":["matweb"],"tags":["brass","c360","machining"]},{"id":"copper-c110","kind":"material","tier":1,"title":"Copper C110 (ETP)","summary":"C110: 8.94 g/cm3, E 117 GPa, yield 69-345 MPa, thermal 391 W/mK, elec 101% IACS, cost 3/5. The conductivity benchmark; gums up in machining.","applies":["bus bar","electrical contact"],"value":{"table":[{"density":8.94,"E":117,"yieldAnnealed":69,"yieldHard":345,"thermalWmK":391,"iacsPct":101,"costClass":3}]},"basis":"MatWeb C11000 ETP copper datasheet","sources":["matweb"],"tags":["copper","c110","electrical"]},{"id":"ti-6al-4v","kind":"material","tier":1,"title":"Titanium Ti-6Al-4V (Grade 5)","summary":"Ti-6Al-4V: 4.43 g/cm3, E 114 GPa, yield 880 MPa, UTS 950 MPa, max temp 400C, cost 5/5. Best strength-to-weight; slow, expensive to machine.","applies":["aerospace part","medical implant"],"value":{"table":[{"density":4.43,"E":114,"yield":880,"uts":950,"elongPct":14,"maxTempC":400,"costClass":5}]},"basis":"MatWeb Ti-6Al-4V datasheet; ASTM B265 grade 5","sources":["matweb","astm-b265"],"tags":["titanium","ti-6al-4v","grade 5"],"check":{"process":"machining","rule":"min_wall_thickness"}},{"id":"plastic-abs","kind":"material","tier":1,"title":"ABS plastic","summary":"ABS: 1.04 g/cm3, E 2.3 GPa, yield 40 MPa, HDT 98C, max temp 80C, cost 2/5. Tough, easy to mold/print; not UV-stable — yellows outdoors.","applies":["injection molded housing","fdm print"],"value":{"table":[{"density":1.04,"E":2.3,"yield":40,"hdtC":98,"maxTempC":80,"costClass":2}]},"basis":"MatWeb generic ABS datasheet; Protolabs material guide","sources":["matweb","protolabs-materials"],"tags":["abs","plastic","injection molding"],"check":{"process":"injection_molding","rule":"min_wall_thickness"}},{"id":"plastic-pc","kind":"material","tier":1,"title":"Polycarbonate (PC)","summary":"PC: 1.20 g/cm3, E 2.4 GPa, yield 62 MPa, HDT 138C, max temp 115C, cost 3/5. Highest impact strength and clarity; stress-cracks with solvents.","applies":["optical part","impact-resistant housing"],"value":{"table":[{"density":1.2,"E":2.4,"yield":62,"hdtC":138,"maxTempC":115,"costClass":3}]},"basis":"MatWeb generic PC datasheet","sources":["matweb"],"tags":["pc","polycarbonate","impact resistant"]},{"id":"plastic-pa6-66","kind":"material","tier":1,"title":"Nylon PA6 / PA66","summary":"PA6/PA66: 1.13 g/cm3, E 2.9 GPa, yield 70 MPa, HDT 75C, max temp 100C, cost 2/5. Low-friction, wear-resistant; hygroscopic, absorbs 3% water.","applies":["gear","bushing"],"value":{"table":[{"density":1.135,"E":2.9,"yield":70,"hdtDryC":75,"maxTempC":100,"costClass":2}]},"basis":"MatWeb generic PA6/PA66 datasheets","sources":["matweb"],"tags":["nylon","pa6","pa66"]},{"id":"plastic-pa12-sls","kind":"material","tier":1,"title":"Nylon PA12 (SLS/MJF powder)","summary":"PA12 (SLS/MJF): 1.01 g/cm3, E 1.75 GPa, yield 46 MPa, HDT 175C, cost 3/5. Default powder-bed nylon — near-isotropic, slightly porous finish.","applies":["sls print","mjf print"],"value":{"table":[{"density":1.01,"E":1.75,"yield":46,"hdtLowC":175,"elongPct":30,"costClass":3}]},"basis":"HP MJF PA12 and Formlabs/Hubs SLS PA12 datasheets","sources":["hp-mjf-materials","matweb"],"tags":["nylon","pa12","sls"],"check":{"process":"sls","rule":"min_wall_thickness"}},{"id":"plastic-pom","kind":"material","tier":1,"title":"POM / Acetal (Delrin)","summary":"POM (Delrin): 1.41 g/cm3, E 2.8 GPa, yield 65 MPa, HDT 110C, max temp 90C, cost 3/5. Lowest friction, best fatigue life; hard to bond.","applies":["precision gear","snap fit"],"value":{"table":[{"density":1.41,"E":2.8,"yield":65,"hdtC":110,"maxTempC":90,"costClass":3}]},"basis":"MatWeb Delrin (DuPont) POM datasheet","sources":["matweb"],"tags":["pom","acetal","delrin"]},{"id":"plastic-petg","kind":"material","tier":1,"title":"PETG","summary":"PETG: 1.27 g/cm3, E 2.1 GPa, yield 50 MPa, HDT 70C, max temp 70C, cost 1/5. Tougher than PLA, far less warp than ABS; FDA grades exist.","applies":["fdm print","food-contact part"],"value":{"table":[{"density":1.27,"E":2.1,"yield":50,"hdtC":70,"maxTempC":70,"costClass":1}]},"basis":"MatWeb generic PETG datasheet","sources":["matweb"],"tags":["petg","fdm","food contact"]},{"id":"plastic-pla","kind":"material","tier":1,"title":"PLA plastic","summary":"PLA: 1.24 g/cm3, E 3.5 GPa, yield 55 MPa, HDT 55C, max temp 55C, cost 1/5. Easiest FDM material — low warp, but brittle and creeps.","applies":["fdm print","prototype"],"value":{"table":[{"density":1.24,"E":3.5,"yield":55,"hdtC":55,"maxTempC":55,"costClass":1}]},"basis":"MatWeb generic PLA datasheet","sources":["matweb"],"tags":["pla","fdm","prototype"],"check":{"process":"fdm","rule":"min_wall_thickness"}},{"id":"plastic-tpu","kind":"material","tier":1,"title":"TPU (95A)","summary":"TPU 95A: 1.21 g/cm3, flex E 26 MPa, elong 500%, shore 95A, max temp 80C, cost 3/5. Flexible FDM filament for hinges and gaskets.","applies":["flexible fdm print","gasket"],"value":{"table":[{"density":1.21,"flexModMPa":26,"elongPct":500,"shoreA":95,"maxTempC":80,"costClass":3}]},"basis":"MatWeb generic TPU 95A datasheet","sources":["matweb"],"tags":["tpu","flexible","fdm"]},{"id":"plastic-pp","kind":"material","tier":1,"title":"Polypropylene (PP)","summary":"PP: 0.90 g/cm3, E 1.5 GPa, yield 30 MPa, HDT 100C, max temp 100C, cost 1/5. Lowest density plastic, best living-hinge fatigue life.","applies":["living hinge","chemical container"],"value":{"table":[{"density":0.9,"E":1.5,"yield":30,"hdtC":100,"maxTempC":100,"costClass":1}]},"basis":"MatWeb generic PP datasheet","sources":["matweb"],"tags":["pp","polypropylene","living hinge"]},{"id":"plastic-hdpe","kind":"material","tier":1,"title":"HDPE","summary":"HDPE: 0.95 g/cm3, E 1.1 GPa, yield 26 MPa, HDT 80C, max temp 100C, cost 1/5. Tough, low-friction, chemically inert; hard to bond.","applies":["tank","cutting board"],"value":{"table":[{"density":0.95,"E":1.1,"yield":26,"hdtC":80,"maxTempC":100,"costClass":1}]},"basis":"MatWeb generic HDPE datasheet","sources":["matweb"],"tags":["hdpe","polyethylene","chemical resistant"]},{"id":"plastic-pmma","kind":"material","tier":1,"title":"Acrylic (PMMA)","summary":"PMMA: 1.19 g/cm3, E 3.0 GPa, yield 70 MPa, HDT 95C, max temp 80C, cost 2/5. Best optical clarity (92%); laser-cuts to a polished edge.","applies":["optical window","display case"],"value":{"table":[{"density":1.19,"E":3,"yield":70,"hdtC":95,"maxTempC":80,"costClass":2}]},"basis":"MatWeb generic PMMA/acrylic datasheet","sources":["matweb"],"tags":["pmma","acrylic","optical"]},{"id":"wood-plywood-birch","kind":"material","tier":1,"title":"Plywood (Baltic birch)","summary":"Birch ply: 0.68 g/cm3, E ~10 GPa, bend ~65 MPa, max temp 150C (chars), cost 2/5. Void-free veneer — the laser-cutting/jig standard.","applies":["laser-cut enclosure","jig"],"value":{"table":[{"density":0.68,"EGPa":10,"bendMPa":65,"maxTempC":150,"costClass":2}]},"basis":"Baltic birch plywood supplier data (Finland/Russia birch, BB/BB grade)","sources":["matweb"],"tags":["plywood","birch","wood"]},{"id":"wood-mdf","kind":"material","tier":1,"title":"MDF board","summary":"MDF: 0.75 g/cm3, E ~3.5 GPa, bend ~35 MPa, max temp 150C (chars), cost 1/5. Uniform, routes cleanly, paints smooth; swells when wet.","applies":["enclosure","painted panel"],"value":{"table":[{"density":0.75,"EGPa":3.5,"bendMPa":35,"maxTempC":150,"costClass":1}]},"basis":"Generic MDF (medium-density fiberboard) supplier data","sources":["matweb"],"tags":["mdf","wood","fiberboard"]},{"id":"wood-oak","kind":"material","tier":1,"title":"Oak (hardwood)","summary":"Oak: 0.75 g/cm3, E ~12.5 GPa, bend ~97 MPa, max temp 150C (chars), cost 3/5. Dense, decay-resistant hardwood; dulls tools fast.","applies":["furniture","structural joinery"],"value":{"table":[{"density":0.75,"EGPa":12.5,"bendMPa":97,"maxTempC":150,"costClass":3}]},"basis":"USDA Forest Products Laboratory Wood Handbook — red oak mechanical properties","sources":["matweb"],"tags":["oak","hardwood","wood"]},{"id":"composite-cf-epoxy","kind":"material","tier":1,"title":"Carbon fiber / epoxy (CFRP, 0/90 woven)","summary":"CFRP woven 0/90: 1.55 g/cm3, E 60-70 GPa, tensile ~575 MPa, max temp 120C, cost 5/5. Best stiffness-to-weight; abrasive to cut.","applies":["drone frame","lightweight structural panel"],"value":{"table":[{"density":1.55,"EGPa":65,"tensileMPa":575,"maxTempC":120,"costClass":5}]},"basis":"MatWeb woven carbon/epoxy laminate datasheet (typical quasi-isotropic layup)","sources":["matweb"],"tags":["carbon fiber","cfrp","composite"]},{"id":"composite-gf-nylon","kind":"material","tier":1,"title":"Glass-fiber filled nylon (PA6-GF30)","summary":"PA6-GF30: 1.36 g/cm3, E ~7 GPa, yield ~120 MPa, HDT 210C, max temp 150C, cost 3/5. 30% glass roughly doubles stiffness over PA6.","applies":["structural bracket","gear housing"],"value":{"table":[{"density":1.36,"EGPa":7,"yieldMPa":120,"hdtDryC":210,"maxTempC":150,"costClass":3}]},"basis":"MatWeb PA6-GF30 datasheet","sources":["matweb"],"tags":["nylon","glass filled","gf30"]},{"id":"sheet-metal-gauge-table","kind":"dimension","tier":2,"title":"Sheet metal gauge to thickness (steel / aluminum / stainless)","summary":"Gauge number does not mean the same thickness per material: 16ga steel = 1.52 mm, 16ga aluminum = 1.29 mm, 16ga stainless = 1.52 mm. Always confirm gauge with the material family before quoting or modeling.","applies":["sheet metal","enclosure","bracket"],"value":{"table":[{"gauge":10,"steelMM":3.42,"alMM":2.59,"ssMM":3.42},{"gauge":12,"steelMM":2.66,"alMM":2.05,"ssMM":2.77},{"gauge":14,"steelMM":1.9,"alMM":1.63,"ssMM":1.91},{"gauge":16,"steelMM":1.52,"alMM":1.29,"ssMM":1.52},{"gauge":18,"steelMM":1.21,"alMM":1.02,"ssMM":1.21},{"gauge":20,"steelMM":0.91,"alMM":0.81,"ssMM":0.95},{"gauge":22,"steelMM":0.76,"alMM":0.64,"ssMM":0.76}]},"basis":"Manufacturers Standard Gauge (steel/stainless) vs the separate Aluminum B&S gauge series","sources":["engineering-toolbox-gauge"],"tags":["gauge","sheet metal","thickness","steel","aluminum","stainless"]},{"id":"standard-stock-sizes","kind":"dimension","tier":2,"title":"Standard bar, plate and tube stock sizes (metric)","summary":"Round bar stocked at 3,4,5,6,8,10,12,16,20,25,30,40,50,60,80,100 mm dia; plate at 1,1.5,2,3,4,5,6,8,10,12,15,20,25 mm; tube walls commonly 1,1.5,2,3 mm. Designing to a stocked size skips a custom-billet lead time and cost adder.","applies":["machined part","weldment","turned part"],"value":{"table":[{"form":"round bar","sizesMM":"3,4,5,6,8,10,12,16,20,25,30,40,50,60,80,100"},{"form":"plate","sizesMM":"1,1.5,2,3,4,5,6,8,10,12,15,20,25,30"},{"form":"square bar","sizesMM":"5,6,8,10,12,15,20,25,30,40,50"},{"form":"tube wall","sizesMM":"1,1.5,2,2.5,3,4,5"}]},"basis":"Common metric mill stock ranges (aluminum/steel/stainless distributors); confirm with the specific supplier","sources":["xometry-materials"],"tags":["stock","bar","plate","tube","standard size"]},{"id":"print-process-material-matrix","kind":"process","tier":2,"title":"3D-print process to material, min wall and tolerance matrix","summary":"FDM PLA/PETG/ABS min wall 0.8mm tol +-0.3mm; SLA resin min wall 0.6mm tol +-0.15mm; SLS PA12 min wall 0.7mm tol +-0.3%; MJF PA12 min wall 0.5mm tol +-0.3mm; DMLS metal min wall 0.8mm tol +-0.1-0.2mm. Pick the process from the material need first, then the wall.","applies":["3d printing","additive manufacturing"],"value":{"table":[{"process":"fdm","materials":"PLA, PETG, ABS, TPU, PA-CF","minWallMM":0.8,"tolMM":0.3},{"process":"sla","materials":"standard/tough/durable resin","minWallMM":0.6,"tolMM":0.15},{"process":"sls","materials":"PA12, PA11, TPU powder","minWallMM":0.7,"tolPct":0.3},{"process":"mjf","materials":"PA12, PA12-GB","minWallMM":0.5,"tolMM":0.3},{"process":"dmls","materials":"17-4PH, Ti-6Al-4V, AlSi10Mg, Inconel 718","minWallMM":0.8,"tolMM":0.15}]},"basis":"ops/dfmRules.js PACKS fdm/sla/sls/mjf/dmls min_wall_thickness limits and each pack limits.general_tolerance","sources":["protolabs-materials","formlabs-materials","hp-mjf-materials"],"tags":["3d printing","fdm","sla","sls","mjf","dmls","material matrix"]},{"id":"material-selection-by-requirement","kind":"rule","tier":2,"title":"Material selection by service requirement","summary":"Outdoor/UV: ASA, PC, 316 stainless, powder-coated aluminum. Food contact: 304/316, PP, HDPE, FDA-listed PETG/nylon. Medical/implant: 316L, Ti-6Al-4V ELI, PEEK. High temp (>150C): PEEK, PPS, 4140 steel, DMLS metals. Chemical exposure: PP, HDPE, PTFE, 316.","applies":[],"value":{"table":[{"requirement":"outdoor / UV","recommended":"ASA, PC, 316 SS, powder-coated 6061"},{"requirement":"food contact","recommended":"304/316 SS, PP, HDPE, FDA PETG/nylon"},{"requirement":"medical / implant","recommended":"316L SS, Ti-6Al-4V ELI, PEEK"},{"requirement":"high temp > 150C","recommended":"PEEK, PPS, 4140 steel, DMLS metal"},{"requirement":"chemical exposure","recommended":"PP, HDPE, PTFE, 316 SS"},{"requirement":"low friction / wear","recommended":"POM, PA6, bronze bushing"}]},"basis":"Cross-reference of supplier material guides against common regulatory/service categories","sources":["protolabs-materials","xometry-materials","fda-usp-class-vi"],"tags":["material selection","outdoor","food contact","medical","high temperature","chemical resistant"]},{"id":"galvanic-compatibility-table","kind":"rule","tier":2,"title":"Galvanic compatibility of common metal pairs","summary":"Metals >~0.25V apart on the galvanic series corrode the less-noble one when wet and touching: aluminum against steel or copper needs an isolating washer/coating; titanium, 300-series stainless and bronze are mutually safe.","applies":["fastener","dissimilar metal assembly","marine hardware"],"value":{"table":[{"pairA":"aluminum","pairB":"steel (bare)","risk":"high - isolate or coat"},{"pairA":"aluminum","pairB":"copper/brass","risk":"high - isolate or coat"},{"pairA":"aluminum","pairB":"304/316 stainless","risk":"moderate - isolate for wet/marine use"},{"pairA":"steel","pairB":"304/316 stainless","risk":"low-moderate - steel sacrifices slowly"},{"pairA":"titanium","pairB":"300-series stainless","risk":"low - mutually compatible"},{"pairA":"zinc-plated steel","pairB":"aluminum","risk":"moderate - zinc sacrifices over time"}]},"basis":"Galvanic series in seawater ranking; risk scales with the voltage gap and electrolyte exposure","sources":["ansys-galvanic"],"tags":["galvanic","corrosion","dissimilar metals","fastener"]},{"id":"food-contact-biocompatible-flags","kind":"rule","tier":2,"title":"Food-contact and biocompatibility flags by material","summary":"304/316 stainless, PP, HDPE, PC (BPA-free) and FDA-listed PETG/nylon grades are commonly food-contact safe (21 CFR 177); biocompatibility (USP Class VI/ISO 10993) needs 316L, Ti-6Al-4V ELI or PEEK, not the standard commercial grade.","applies":["food equipment","medical device","consumer product"],"value":{"table":[{"material":"304/316 stainless","foodContact":true,"biocompatible":"implant grade (316L) only"},{"material":"PP / HDPE","foodContact":true,"biocompatible":false},{"material":"PC (BPA-free grade)","foodContact":true,"biocompatible":false},{"material":"PA12 (medical grade)","foodContact":false,"biocompatible":"ISO 10993 grades exist"},{"material":"Ti-6Al-4V ELI","foodContact":false,"biocompatible":true},{"material":"PEEK (medical grade)","foodContact":false,"biocompatible":true}]},"basis":"FDA 21 CFR 177 food-contact substance list; USP Class VI / ISO 10993 biocompatibility testing scope","sources":["fda-usp-class-vi"],"tags":["food contact","biocompatible","fda","usp class vi","medical"]},{"id":"wall-thickness-by-material-process","kind":"rule","tier":2,"title":"Minimum wall thickness by material family and process","summary":"The floor is set by process, not material: machining >=0.8mm, injection molding >=1.0mm, sheet metal >=0.5mm, FDM >=0.8mm, SLA >=0.6mm, SLS >=0.7mm, MJF >=0.5mm, DMLS >=0.8mm. Use cad_dfm_check per process, not one blanket number.","applies":[],"value":{"table":[{"process":"machining","minWallMM":0.8},{"process":"injection_molding","minWallMM":1},{"process":"sheet_metal","minWallMM":0.5},{"process":"fdm","minWallMM":0.8},{"process":"sla","minWallMM":0.6},{"process":"sls","minWallMM":0.7},{"process":"mjf","minWallMM":0.5},{"process":"dmls","minWallMM":0.8}]},"basis":"ops/dfmRules.js PACKS[*].rules.min_wall_thickness — the enforced floor per process","sources":["protolabs-materials"],"tags":["wall thickness","process","min wall","dfm"],"check":{"process":"machining","rule":"min_wall_thickness"}},{"id":"service-temperature-by-material-class","kind":"rule","tier":2,"title":"Continuous service temperature by material class","summary":"Rough continuous-service ceilings: commodity plastics 50-80C, engineering plastics 90-115C, high-performance plastics 150-250C, aluminum 120-150C, carbon steel 400C+, stainless 800C+, titanium ~400C before surface oxidation.","applies":[],"value":{"table":[{"class":"commodity plastic","maxTempC":70},{"class":"engineering plastic","maxTempC":105},{"class":"high-performance plastic","maxTempC":200},{"class":"aluminum alloy","maxTempC":135},{"class":"carbon/alloy steel","maxTempC":425},{"class":"stainless steel","maxTempC":800},{"class":"titanium alloy","maxTempC":400}]},"basis":"Midpoints of HDT/service-temperature ranges published across the tier-1 material entries in this pack","sources":["matweb","protolabs-materials"],"tags":["temperature","service temperature","material class"]},{"id":"corrosion-resistance-by-material-class","kind":"rule","tier":2,"title":"Corrosion resistance by material class (uncoated)","summary":"Uncoated bare-metal ranking, best to worst: titanium and 316 stainless (excellent) > 304 stainless > aluminum (self-passivating) > brass/bronze/copper (patinas) > carbon/alloy steel (rusts, needs coating or oil).","applies":[],"value":{"table":[{"material":"titanium / 316 stainless","rating":"excellent"},{"material":"304 stainless","rating":"very good"},{"material":"aluminum (bare)","rating":"good, self-passivating"},{"material":"brass / bronze / copper","rating":"fair, patinas"},{"material":"carbon / alloy steel (uncoated)","rating":"poor, needs coating"}]},"basis":"Standard atmospheric/mild-chemical corrosion behavior summarized from supplier material guides","sources":["matweb","protolabs-materials"],"tags":["corrosion","material class","coating"]},{"id":"al-6063-t5","kind":"material","tier":2,"title":"Aluminum 6063-T5 (extrusion)","summary":"6063-T5: 2.70 g/cm3, E 68.9 GPa, yield 145 MPa, UTS 186 MPa, max temp 150C, cost 2/5. Lower strength than 6061 but extrudes into far more complex thin-wall profiles and takes a better anodized finish — the T-slot/frame-rail alloy.","applies":["aluminum extrusion","frame rail","trim"],"value":{"table":[{"density":2.7,"E":68.9,"yield":145,"uts":186,"maxTempC":150,"costClass":2}]},"basis":"MatWeb 6063-T5 datasheet; ASTM B221 extrusion standard","sources":["matweb","astm-b221"],"tags":["aluminum","6063","extrusion","frame"]},{"id":"steel-a36","kind":"material","tier":2,"title":"Structural steel A36","summary":"A36: 7.85 g/cm3, E 200 GPa, yield 250 MPa, UTS 400-550 MPa, elong 20%, max temp 400C, cost 1/5. The generic structural-plate steel — good weldability, no guaranteed hardenability; specify 1018/1045 instead when a machined finish matters.","applies":["weldment","plate frame","structural bracket"],"value":{"table":[{"density":7.85,"E":200,"yield":250,"uts":450,"elongPct":20,"maxTempC":400,"costClass":1}]},"basis":"ASTM A36/A36M specification","sources":["astm-a36"],"tags":["steel","a36","structural","weldment"]},{"id":"ss-17-4ph","kind":"material","tier":2,"title":"Stainless steel 17-4PH (H900)","summary":"17-4PH H900: 7.75 g/cm3, E 196 GPa, yield 1170 MPa, UTS 1310 MPa, elong 10%, max temp 315C, cost 4/5. Precipitation-hardening stainless — near-4140 strength with better corrosion resistance; age at 480-620C after machining for full properties.","applies":["high-strength stainless part","valve component","aerospace fitting"],"value":{"table":[{"density":7.75,"E":196,"yield":1170,"uts":1310,"elongPct":10,"maxTempC":315,"costClass":4}]},"basis":"MatWeb 17-4PH H900 datasheet","sources":["matweb"],"tags":["stainless","17-4ph","precipitation hardening","high strength"]},{"id":"cast-iron-gray","kind":"material","tier":2,"title":"Gray cast iron (Class 30)","summary":"Gray iron Class 30: 7.15 g/cm3, E 100-145 GPa, UTS 207 MPa (min), compressive ~700 MPa, max temp 400C, cost 1/5. Excellent vibration damping and compressive strength, poor tensile/impact — brittle; cast, not welded, machines with a graphite-lubricated chip.","applies":["machine base","engine block","vibration-damping fixture"],"value":{"table":[{"density":7.15,"EGPa":120,"utsMPa":207,"compressiveMPa":700,"maxTempC":400,"costClass":1}]},"basis":"MatWeb ASTM A48 Class 30 gray iron datasheet","sources":["matweb"],"tags":["cast iron","gray iron","machine base","damping"]},{"id":"zinc-zamak3","kind":"material","tier":2,"title":"Zinc die-cast alloy (Zamak 3)","summary":"Zamak 3: 6.60 g/cm3, E 96 GPa, yield 176 MPa, UTS 283 MPa, elong 10%, max temp 100C, cost 2/5. Casts to tight tolerance with a fine as-cast finish at lower tooling cost than aluminum die-casting; not for sustained load above 100C (creeps).","applies":["die-cast housing","decorative hardware","connector shell"],"value":{"table":[{"density":6.6,"E":96,"yield":176,"uts":283,"elongPct":10,"maxTempC":100,"costClass":2}]},"basis":"MatWeb Zamak 3 (ASTM AG40A) datasheet","sources":["matweb"],"tags":["zinc","zamak","die casting","zamak 3"]},{"id":"steel-spring-1075","kind":"material","tier":2,"title":"Spring steel 1075 / music wire","summary":"1075 spring temper: 7.85 g/cm3, E 200 GPa, yield ~1300 MPa, UTS ~1450 MPa, max temp 250C, cost 2/5. High carbon, oil-quenched-and-tempered for elastic (not plastic) deflection — flat springs, wire forms; music wire (ASTM A228) is the cold-drawn round-wire equivalent.","applies":["leaf spring","wire spring","snap clip"],"value":{"table":[{"density":7.85,"E":200,"yieldMPa":1300,"utsMPa":1450,"maxTempC":250,"costClass":2}]},"basis":"MatWeb 1075 spring-temper steel and ASTM A228 music wire datasheets","sources":["matweb","sae-j403"],"tags":["spring steel","1075","music wire","spring"]},{"id":"tool-steel-comparison","kind":"material","tier":2,"title":"Tool steel comparison (O1 / A2 / D2)","summary":"O1 (oil-hardened): yield ~1380 MPa, easiest to harden. A2 (air-hardened): yield ~1500 MPa, less distortion. D2 (high-Cr): yield ~1700 MPa, best wear/edge retention, hardest to grind. ~7.8 g/cm3, service to 230C tempered.","applies":["stamping die","cutting tool","wear-resistant fixture"],"value":{"table":[{"density":7.8,"o1YieldMPa":1380,"a2YieldMPa":1500,"d2YieldMPa":1700,"maxTempC":230,"costClass":3}]},"basis":"MatWeb O1/A2/D2 tool steel datasheets","sources":["matweb"],"tags":["tool steel","o1","a2","d2","die"]},{"id":"bronze-c932","kind":"material","tier":2,"title":"Bearing bronze C932","summary":"C932 (SAE 660): 8.64 g/cm3, E 103 GPa, yield 152 MPa, UTS 241 MPa, elong 20%, max temp 260C, cost 4/5. High-tin bronze cast bushing alloy — self-lubricating with graphite/oil impregnation, standard for sleeve bearings and worm gears against steel shafts.","applies":["bushing","sleeve bearing","worm gear"],"value":{"table":[{"density":8.64,"E":103,"yield":152,"uts":241,"elongPct":20,"maxTempC":260,"costClass":4}]},"basis":"MatWeb C93200 (SAE 660) bearing bronze datasheet","sources":["matweb"],"tags":["bronze","c932","bushing","bearing"]},{"id":"plastic-peek","kind":"material","tier":2,"title":"PEEK","summary":"PEEK: 1.32 g/cm3, E 3.6 GPa, yield 100 MPa, HDT 152C, max temp 250C, cost 5/5. Highest continuous-use temperature and chemical resistance of common engineering plastics, autoclavable and implant-gradable; the most expensive plastic in routine use.","applies":["high-temp part","chemical-resistant seal","medical implant"],"value":{"table":[{"density":1.32,"E":3.6,"yield":100,"hdtC":152,"maxTempC":250,"costClass":5}]},"basis":"MatWeb generic PEEK (unfilled) datasheet","sources":["matweb"],"tags":["peek","high temperature","chemical resistant","medical"]},{"id":"plastic-asa","kind":"material","tier":2,"title":"ASA plastic","summary":"ASA: 1.07 g/cm3, E 2.1 GPa, yield 45 MPa, HDT 100C, max temp 85C, cost 2/5. The UV-stable alternative to ABS — same processability and impact strength without yellowing/embrittling outdoors; the default choice for any part that lives in sunlight.","applies":["outdoor enclosure","automotive trim","fdm print"],"value":{"table":[{"density":1.07,"E":2.1,"yield":45,"hdtC":100,"maxTempC":85,"costClass":2}]},"basis":"MatWeb generic ASA datasheet","sources":["matweb"],"tags":["asa","uv stable","outdoor","fdm"]},{"id":"plastic-hips","kind":"material","tier":2,"title":"HIPS","summary":"HIPS: 1.04 g/cm3, E 2.1 GPa, yield 22 MPa, HDT 88C, max temp 70C, cost 1/5. Dissolves in limonene (common FDM dual-extrusion support material for ABS); also a cheap vacuum-forming sheet stock — lower strength/UV resistance than ABS.","applies":["fdm support material","vacuum-formed panel","low-cost enclosure"],"value":{"table":[{"density":1.04,"E":2.1,"yield":22,"hdtC":88,"maxTempC":70,"costClass":1}]},"basis":"MatWeb generic HIPS datasheet","sources":["matweb"],"tags":["hips","support material","vacuum forming"]}]}