Why Material Choice Matters: Polycarbonate vs. ABS

Rising costs across the supply chain are placing increasing importance on material selection. In lighting design, these decisions go far beyond aesthetics—they are critical to ensuring long-term performance, safety, and durability.

While Acrylonitrile Butadiene Styrene (ABS) has traditionally been widely used in plastic manufacturing due to its cost-effectiveness, at Aurora Lighting we prioritise the use of Polycarbonate (PC) across our Good and Better product tiers. From downlights to IP-rated outdoor fixtures, our choice of PC reflects both its superior performance in demanding environments and our commitment to delivering long-lasting, high-quality solutions.

The Performance Edge: Polycarbonate vs. ABS

When comparing these two materials, Polycarbonate consistently outperforms ABS in key areas that define reliability and product lifespan.

1. Durability and Impact Resistance

Polycarbonate is often described as virtually unbreakable. While ABS does offer some impact resistance, it is significantly more brittle in comparison. In lighting applications—where fixtures may experience knocks during installation or require anti-vandal properties—PC provides the robustness needed to ensure products remain intact and fully functional.

2. Advanced Heat Resistance

Lighting fixtures, particularly those using high-output LEDs, generate considerable heat. Material stability under these conditions is essential.

• ABS begins to deform at approximately 90°C – 100°C
• PC maintains structural integrity up to 130°C – 135°C

This enhanced thermal resistance helps prevent warping and discolouration of housings and diffusers, ensuring consistent light output, beam angle, and appearance over time.

3. Reliable IP Ratings and Sealing

Achieving and maintaining high Ingress Protection (IP) ratings—such as IP65 and above for outdoor lighting—requires precise sealing against dust and water.

Polycarbonate offers superior dimensional stability, meaning it is less prone to expansion or shrinkage under temperature changes. This allows for tighter tolerances and more effective gasket performance, making PC the preferred material for outdoor installations where reliability is critical.

4. UV Resistance: Maintaining Appearance and Strength

One of the key limitations of ABS is its poor resistance to UV exposure. Over time, sunlight can cause ABS to yellow and become brittle.

Polycarbonate, especially when enhanced with UV stabilisers, is designed to withstand prolonged exposure to sunlight. This ensures that fixtures retain their original colour and structural integrity—avoiding the aged, yellowed appearance often seen in lower-quality materials.

Sustainability and Long-Term Value

Although Polycarbonate has a higher initial material cost than ABS, it offers a lower total cost of ownership.

• Longer product lifespan
• Reduced maintenance and replacement needs
• Lower volumes of waste sent to landfill

Additionally, PC is a highly recyclable thermoplastic, supporting both Aurora Lighting’s sustainability goals and those of our customers.

Aurora Lighting: A Commitment to Quality

As a leader in the lighting industry, Aurora Lighting has standardised the use of high-grade Polycarbonate across much of its product range. This includes popular solutions such as the Utilite Bulkhead range, Poly-Slim™ Downlights, and R6 Fire Rated Downlights.

By selecting PC for bezels and housings, we ensure our products deliver the heat resistance, durability, and IP-rated protection required for professional installations.

Our commitment to premium materials guarantees that Aurora products remain safe, reliable, and visually consistent throughout their operational life—providing confidence to installers, specifiers, and end users alike.