What if you could get a plastic that takes a beating but doesn’t drain your budget? Good news—several options fit that bill.
HDPE costs around $0.60–$1.00 per pound. Yet it handles chemicals, UV rays, and rough use without cracking. That’s the kind of value most buyers want.
This guide breaks down five top choices for cheap but strong plastic so you can pick the right material without second-guessing yourself. We’ll compare ABS, HDPE, PVC, HIPS, and PETG side by side. You’ll see real strength numbers, best uses, and the trade-offs for each one.
The best cheap but strong plastics are ABS, HDPE, and PVC. ABS costs around $1.00–$1.50 per pound and delivers excellent impact resistance—think LEGO bricks. HDPE runs about $0.60–$1.00 per pound with great chemical and UV resistance. It works well for outdoor furniture and containers. PVC offers stiffness and moisture resistance at low cost. That makes it a go-to for pipes and construction.
Two other budget options include HIPS and PETG. HIPS is easy to thermoform and remains one of the most affordable plastics on the market. PETG is nearly unbreakable with good clarity.
Your best pick depends on the environment. Choose HDPE or PVC for chemical exposure. Pick PETG when you need transparency. Go with ABS for tough housings that stay indoors.
Some plastics cost less because factories make huge amounts of them. Polypropylene, polyethylene, PVC, and polystyrene fall into this group. High production volume keeps prices low.
“Strength” means different things depending on your project. Tensile strength measures how much pull a plastic can take before it breaks. Impact strength shows how well it handles sudden hits. Flexural strength tells you how much bending it can take. Chemical resistance matters when parts touch solvents, oils, or acids. These properties are measured using standardized testing methods from ASTM International, the global authority on materials testing.
No single plastic wins in every category. Each one has trade-offs. A plastic that handles impact well might soften in high heat. One that resists chemicals might scratch easily.
Your project environment narrows the field. Ask yourself: Will this part live indoors or outdoors? Will it face UV rays, chemicals, or extreme temps? The answers point you toward the right material.
Clients often ask for “the strongest” plastic. But the real question is strongest for what? Once we know the job, we can match the material.
ABS stands for acrylonitrile butadiene styrene. It’s one of the most popular plastics for parts that need to take a hit.
Cost: Around $1.00–$1.50 per pound.
Tensile strength: 40–50 MPa.
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If you need even more strength, ABS-PC blends can significantly boost performance. These blends mix ABS with polycarbonate for tougher results and better heat resistance.
ABS works best for indoor parts that face bumps, drops, or regular handling. It gives you a clean look and solid performance without a high price tag.
HDPE stands for high-density polyethylene. It offers the best bang for your buck when parts face sun, rain, or harsh chemicals.
Cost: Around $0.60–$1.00 per pound.
Tensile strength: 21–30 MPa.
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How does HDPE compare to LDPE? HDPE is stiffer and stronger. LDPE is more flexible. Pick HDPE when you need rigid parts that hold their shape.
We’ve molded HDPE parts for outdoor signage here in Cache Valley that lasted years without cracking. The material handles Utah’s hot summers and cold winters with ease.
PVC stands for polyvinyl chloride. It’s a workhorse in construction and plumbing because of its stiffness and low cost.
Cost: Low. PVC is a commodity plastic with wide availability.
Tensile strength: Around 6,000–7,500 psi for rigid PVC.
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Rigid PVC and flexible PVC serve different jobs. Rigid PVC works for structural parts like pipes and frames. Flexible PVC uses plasticizers to bend. You’ll find it in hoses, cable jackets, and inflatable products.
For building projects that need strength at a low price, rigid PVC is hard to beat. It holds up to moisture and won’t rot like wood.
Not sure which plastic fits? Learn more about our team and how we help clients choose the right material.
HIPS stands for high-impact polystyrene. It’s one of the cheapest plastics you can buy, and it forms into shapes with ease.
Cost: Among the lowest of all thermoplastics. Prices vary with market conditions but typically run well below ABS.
Tensile strength: Moderate. Lower than ABS.
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When does HIPS beat ABS? Choose HIPS when cost matters most and stress levels stay low. It works well for parts that don’t face hard hits or harsh weather.
HIPS also makes a great choice for prototypes. You can test a design at low cost before committing to a pricier material. Once you prove the shape works, you can switch to ABS or another plastic for production runs.
PETG stands for polyethylene terephthalate glycol. It gives you clear, tough parts without the high price of polycarbonate.
Cost: Moderate. Less than polycarbonate.
Tensile strength: Good, with excellent impact resistance.
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How does PETG compare to polycarbonate? PETG costs less and forms easier. Polycarbonate offers higher strength and better clarity. If your project needs clear parts but doesn’t face extreme stress, PETG saves money without giving up much performance.
PETG also works well for parts that need sterilization. Many medical and food service items use it because it cleans easily and meets safety standards.
Picking the right plastic comes down to where your part will live and what it will face. Ask these questions before you decide:
Quick-reference guide:
| Plastic | Cost/lb (approx.) | Tensile Strength | Best For |
| ABS | $1.00–$1.50 | 40–50 MPa | Housings, toys, automotive |
| HDPE | $0.60–$1.00 | 21–30 MPa | Outdoor, containers, pipes |
| PVC | Low | ~6,000–7,500 psi | Construction, plumbing |
| HIPS | Very low | Moderate | Packaging, displays |
| PETG | Moderate | Good | Clear parts, signage |
Your molding method matters too. Injection molding optimizes strength and consistency. The process packs material tight and removes weak spots. A well-designed mold brings out the best in any plastic.
When clients aren’t sure which material fits, we run a quick stress analysis to match material to load. It saves rework later and gets your project right the first time.
Ready to start your project? Contact Freeform Polymers and we’ll help you choose the right material for your application.
