Material Comparison Tool
Compare metals side by side — density, strength, cost, corrosion resistance, weight, and when to use each. Select 2 or 3 materials to compare.
Select materials to compare (2-3)
Material Cost — 100×100×3mm Part
MS$0.71 (cheapest)
304$2.16
Al$0.96
Weight — 100×100×3mm Part
MS236g
304240g
Al80g (lightest)
| Property | Mild Steel | Stainless Steel 304 | Aluminium 5052 |
|---|---|---|---|
| Density | 7.85 g/cm³ | 8 g/cm³ | 2.68 g/cm³ |
| Tensile Strength | 400–550 MPa | 515 MPa | 230 MPa |
| Yield Strength | ~250 MPa | 205 MPa | 195 MPa |
| Elongation | ~20% | ~40% | ~12% |
| Melting Point | 1,425–1,540°C | 1,400–1,450°C | ~660°C |
| Material Cost | ~$3/kg | ~$9/kg | ~$12/kg |
| Magnetic | Yes | No | No |
| Corrosion Resistance | Poor | Good | Excellent |
| Weldability | Excellent | Good | Excellent |
| Machinability | Good | Fair | Fair |
| Laser Cuttable | Yes | Yes | Yes |
| Max Laser Thickness | 20mm | 12mm | 16mm |
| Available Finishes | Powder coat, galvanise, zinc plate, paint | 2B mill, brushed, mirror, electropolish, passivation | Anodise (clear, black, colours), powder coat, brushed |
Mild Steel
Best For
- General fabrication
- Structural brackets
- Enclosures
- Guards
- Painted parts
Limitations
- Rusts without coating
- Heavy
- Not food-safe without coating
Stainless Steel 304
Best For
- Food/beverage equipment
- Kitchen/medical
- Architectural
- Indoor corrosion resistance
Limitations
- 3x material cost of MS
- Slower laser cutting
- Work-hardens during machining
Aluminium 5052
Best For
- Lightweight parts
- Outdoor without coating
- Marine/solar
- Anodised parts
Limitations
- Lower strength than steel
- ~4x material cost per kg
- Scratches easily
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Frequently Asked Questions
What is the cheapest material for laser cutting?
Mild steel is the most affordable material for laser cutting, at roughly $3/kg. It cuts fastest, so machine time costs are also lowest. Galvanised steel is slightly more expensive but eliminates the need for painting. Aluminium is roughly 4x the material cost per kg, but is much lighter — for large, thin parts the weight-based cost difference narrows.
When should I use stainless steel instead of mild steel?
Use stainless steel when the part will be exposed to moisture, chemicals, food contact, or salt air without being painted. Stainless 304 is suitable for most indoor and mild outdoor applications. Stainless 316 is required for marine, coastal, and chemically aggressive environments. If the part will be powder coated or painted, mild steel is usually more cost-effective.
Is aluminium stronger than steel?
No — steel is stronger in absolute terms. Mild steel has a tensile strength of 400–550 MPa compared to aluminium 5052 at 230 MPa. However, aluminium has a better strength-to-weight ratio because it is roughly one-third the density of steel. For weight-sensitive applications (aerospace, automotive, portable equipment), aluminium can provide adequate strength at significantly less weight.
What material is best for outdoor use without painting?
For outdoor parts that won't be painted: aluminium 5052 (naturally forms a protective oxide, lightweight), stainless 304 (excellent corrosion resistance, strong), stainless 316 (coastal/marine environments), or galvanised steel (pre-coated, cost-effective). Corten (weathering steel) develops a protective rust patina and is popular for garden design, signage, and architectural features. Mild steel, copper, and brass will all corrode or tarnish without a protective coating.
What is Corten steel and when should I use it?
Corten (also called weathering steel) is a steel alloy that develops a stable, protective rust-coloured patina when exposed to weather over 6-12 months. It is popular for garden planters, decorative screens, signage, landscape edging, and architectural features where the rustic appearance is desired. It costs about 40% more than mild steel but requires no coating or maintenance. Avoid using it in enclosed spaces or where rust staining on adjacent surfaces (concrete, paving) would be a problem.