When designing a new product or component, selecting the right material is crucial. Whether you need something lightweight, strong, durable, or cost-effective, the choice of material can make all the difference in performance and longevity.
Two popular options for high-performance applications are G10 and phenolic. Both are versatile composites known for their excellent mechanical properties, electrical insulation, and resistance to chemicals and moisture. But with so many similarities, how do you decide which one is the best fit for your project?
In this article we’ll break down key considerations, common applications, similarities and differences of these popular composites.
Key Considerations When Choosing G10 vs Phenolic
When selecting a material, consider the following factors:
- Weight: Lightweight materials are often crucial for applications where minimizing mass is important.
- Electrical Insulation: For components involving electronics, the material should have good electrical insulating properties.
- Environmental Resistance: The material must withstand various conditions, such as exposure to moisture, chemicals, and temperature fluctuations.
- Mechanical Strength: The material should be strong enough to resist impact and wear.
- Cost: Cost-effectiveness is key, especially for high-volume production.
Two Top Contenders: G10 and Phenolic
Two popular materials that often come up in high-performance applications are G10 and phenolic. Both materials meet many of the requirements for strength, durability, and resistance to environmental factors, making them suitable for a wide range of uses.
G10 and phenolic are:
- High-pressure laminates (composites)
- Strong and tough
- Resistant to impact, chemicals, and corrosion
- Electrically insulative
- Lightweight and relatively inexpensive (compared to premium materials like carbon fiber)
At SendCutSend we stock G-10 (FR-4 Grade) in four thicknesses ranging from .063″ – .375″. Our G-10 is cut on our waterjet with +/- .009″ cutting tolerance.
LE Phenolic Linen (Micarta) is offered in three thicknesses; .125″, .250″, and .375″ and is also cut on our waterjet with +/- .009″ cutting tolerance.
Common Applications of G10 vs Phenolic
Due to their beneficial properties, G10 and phenolic are used in various applications, including:
- Circuit boards and insulators
- Tactical gear (such as flashlight handles and grips)
- Kitchenware and household appliances
- Mechanical components like brackets, spacers, gears, and pulleys
What Sets G10 Apart from Phenolic?
The primary difference between G10 and phenolic lies in their construction:
- Phenolic: Made from layers of paper or fabric soaked in phenolic resin, then stacked and pressed together under high pressure.
- G10: Consists of fiberglass fabric impregnated with an epoxy resin binder, often referred to as prepreg. This type of material is common in aerospace structures, high-end sporting goods, and wind turbine blades.
Key Differences: Machinability and Performance of G10 vs Phenolic
Here are the main distinctions between G10 and phenolic:
- Machinability:
- G10 is fairly abrasive, which can wear down cutting tools faster, potentially increasing machining costs for complex parts.
- Phenolic is less abrasive and can be more cost-effective for parts requiring extensive machining.
- Performance:
- G10 generally offers slightly better performance in terms of strength, durability, and resistance across all categories.
- Phenolic still provides excellent performance for many applications but at a lower cost.
- G10 is approximately 30% more expensive than phenolic, which may influence material choice in high-volume applications where cost is a concern.
Making Your Choice: G10 or Phenolic?
Choosing between G10 and phenolic depends on your specific needs:
- For higher strength and durability: G10 might be the better choice, especially for applications where superior performance is critical.
- For cost-sensitive projects: Phenolic could be more suitable due to its lower price, particularly in high-volume production scenarios.
If your design involves secondary machining operations, such as countersinking holes or creating intricate shapes, consider how each material’s properties will impact the overall cost and suitability.
Explore Your Options for Custom Composite Parts
Ultimately, both G10 and phenolic have their unique advantages. Depending on your project’s requirements, one may be more suitable than the other. Take the time to experiment with different materials and manufacturing options to find the best fit for your needs. By making an informed choice, you can ensure your project is both successful and cost-effective.
