Hello! Polycarbonate is impact and temperature-resistant but can sometimes be unforgiving when it comes to complex geometries that need to go through repeated load/unload cycles. While polycarbonate can be successfully used for snap joints, extra care must be taken when designing the joint. A polycarbonate/ABS blend is impact resistant and slightly more flexible than PC making it ideal for your type of application that requires impact resistance while also being suitable for snap-fit joints.

Polycarbonate is notoriously difficult to mold due to its poor flowability. One of the main benefits of the PC/ABS blend is its enhanced flowability. Additionally, the PC/ABS blend has lower mold shrinkage and as a result, reduced warping. Moldability should be a key consideration when deciding on a material. The material can have all the correct mechanical and thermal properties on paper, but if it’s difficult to mold then it can easily derail your project due to increased wastage and generally poor-quality parts.

For snap-fit enclosures with frequent opening/closing (~20x/week), ABS/PC blend outperforms pure PC at 70°C:

Stress-whitening resistance: ABS enhances flexibility, reducing stress concentration vs. brittle-prone PC;
Fatigue durability: ABS/PC maintains toughness under cyclic stress (PC may embrittle);
Thermal stability: Quality ABS/PC blends have HDT of 90-110°C, ensuring dimensional stability at 70°C;
Moldability: Better flow than PC for intricate snap-fit details.
Recommend: High-flow, high-HDT ABS/PC (e.g., Covestro Bayblend® T65) + optimized snap-fit radii/wall thickness to minimize stress peaks.