Plastic vs. Metal: When to Choose Extrusion Over Fabrication

When it comes to component design, both metal and plastic have their place. But in many applications, extruded plastics offer a smarter, more efficient alternative to metal fabrication — especially when cost, weight, or corrosion resistance are top priorities.

At Lincoln Plastics, we help OEMs evaluate when plastic extrusion makes sense and when metal still might be the better fit. The goal isn’t to replace metal everywhere — it’s to understand which material supports your performance, cost, and production goals best.

1️⃣ Weight and Efficiency

Plastic extrusions are significantly lighter than metal, reducing handling effort, shipping costs, and overall product weight. In assemblies or equipment where weight reduction translates directly to energy or labor savings, plastic extrusion often wins on efficiency.

2️⃣ Corrosion and Environmental Resistance

Unlike steel or aluminum, plastics don’t rust or corrode. For outdoor applications, irrigation systems, or environments with moisture or chemicals, plastic components can offer longer service life and less maintenance — without the need for coatings or treatments.

3️⃣ Manufacturing Flexibility

Extrusion allows for continuous profiles with complex shapes that can be difficult or expensive to achieve with metal fabrication. Integrating multiple functions into a single plastic profile can also reduce the need for fasteners, welds, or assembly labor.

4️⃣ Cost and Production Volume

Metal components often require cutting, welding, or machining — processes that add cost and time. Once tooling is complete, extrusion offers faster, more consistent production at a lower per-part cost for medium to high run quantities.

That said, low-volume or high-load applications may still favor metal. The right choice depends on the specific performance requirements and total cost over the product’s lifespan.

5️⃣ Appearance and Branding Options

With extrusion, it’s easy to incorporate custom colors, striping, or surface finishes directly into the part. This eliminates secondary finishing processes and supports brand consistency across product lines.

Making the Right Choice

Choosing between plastic and metal isn’t about better or worse — it’s about fit. When performance, cost, and efficiency align, extrusion offers a proven path to durable, lightweight, and corrosion-resistant components.

At Lincoln Plastics, we work with OEMs to design the best solution for the job — whether that means plastic, metal, or a combination of both.

Contact us today to discuss whether extrusion could be the right choice for your next project.

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