Choosing the right material for your product isn’t just about what looks good or fits your budget. It’s one of the most important decisions you’ll make in the product development process. The right material can make your product durable, safe, and cost-effective. The wrong one? It could lead to performance issues, customer complaints, or even product recalls.
At Shark Design, we work with startups and established brands across the globe to ensure that the materials used in their products align with function, form, and sustainability. Whether you’re designing a high-end consumer gadget or a mass-market kitchen tool, selecting the right material is the foundation of successful product design.
Let’s break down how to choose the best materials for your product—step by step.
Why Material Selection Matters
Material selection directly impacts your product’s performance, safety, aesthetic appeal, and cost to manufacture. Here’s why it’s not a decision to take lightly:
Performance & Functionality
- Materials determine how your product functions under stress.
- For example, a phone case made of silicone may absorb shock better than hard plastic.
- High-heat environments need materials with excellent thermal resistance.
User Safety
- Especially in food, baby, or medical products, non-toxic, BPA-free, and hypoallergenic materials are essential.
- Choosing certified materials ensures compliance with health and safety regulations.
Sustainability
- Consumers today are more eco-conscious.
- Materials like recycled plastics or biodegradable composites can make your product stand out in a crowded market.
Cost & Manufacturing Scalability
- Materials influence everything from tooling costs to production timelines.
- For instance, thermoplastics may reduce production costs in injection molding due to faster cycle times.
When materials match your product’s use case, you get better durability, happier customers, and fewer surprises during manufacturing.
Key Factors to Consider When Choosing Materials
Selecting the ideal material involves more than just picking what’s popular. It’s about asking the right questions based on your product’s goals.
1. Functionality
What conditions must the product endure?
- Outdoor use? UV-resistant and weatherproof materials like ABS or anodized aluminum.
- Heat exposure? Consider high-heat plastics like polycarbonate or silicone.
- Flexibility needed? TPU or silicone may outperform rigid options.
2. Aesthetics
How should your product look and feel?
- Surface texture: Matte, glossy, rubbery, or metallic.
- Color options: Some materials accept dyes or finishes better than others.
- User perception: Metal feels premium, while plastic may feel lightweight or budget-friendly.
3. Manufacturing Process Compatibility
Is your chosen material compatible with your production method?
- Injection molding: Works well with ABS, polypropylene, and nylon.
- 3D printing: PLA and resin-based materials are ideal for prototyping.
- CNC machining: Common with metals like aluminum and stainless steel.
4. Regulations & Compliance
Does your material need to meet specific safety or legal standards?
- Medical devices: Must meet ISO 10993 biocompatibility standards.
- Food-grade products: Use FDA-approved materials like food-safe silicone.
- Electronics: Flame-retardant and RoHS-compliant materials are crucial.
5. Budget Constraints
Balance quality with cost-effectiveness.
- Premium materials add appeal but may increase unit cost.
- Sometimes, hybrid approaches (e.g., plastic body + metal trim) offer the best of both worlds.
- Consider lifecycle cost: a durable material might reduce replacements or warranty claims.
Common Materials & Their Best Uses
Different materials bring different benefits. Here’s a breakdown of some popular options, with pros, cons, and ideal use cases.
Plastics
Common types: ABS, Polypropylene (PP), Polycarbonate (PC)
Pros:
- Lightweight, low-cost
- Moldable into complex shapes
- Compatible with many finishes
Cons:
- Can degrade under UV exposure
- Less durable than metal
Best for: Consumer products, electronics casings, packaging
Eco Tip: Look into recycled polypropylene or bio-based plastics for sustainability.
Metals
Common types: Aluminum, Stainless Steel, Zinc Alloy
Pros:
- Strong and durable
- Conductive and heat-resistant
- Premium aesthetic feel
Cons:
- Heavier than plastics
- Higher production cost (tooling, machining)
Best for: Tools, hardware, structural components, wearables
Eco Tip: Aluminum is highly recyclable and retains properties post-recycling.
Wood
Common types: Solid hardwood, Bamboo, Engineered wood
Pros:
- Warm, natural look
- Renewable material
- Can be machined or laser cut
Cons:
- Sensitive to humidity and water
- Needs protective coating
Best for: Home décor, furniture, packaging, gift items
Eco Tip: Bamboo is a rapidly renewable resource, making it a great green alternative.
Composites
Common types: Carbon Fiber, Fiberglass, GFRP
Pros:
- Lightweight and ultra-strong
- Resistant to corrosion
Cons:
- High cost
- Complex manufacturing
Best for: Aerospace, automotive, high-performance products
Sustainable Alternatives
Types: Bioplastics (PLA), Mycelium, Recycled materials
Pros:
- Biodegradable or compostable
- Great for eco-conscious branding
Cons:
- Often less durable than traditional materials
- Limited shelf life or heat resistance
Best for: Packaging, single-use items, eco-product lines
Case Study: Shark Design’s Smart Material Solution
One of our clients approached us with an idea for a kitchen gadget—a reusable, heat-resistant food gripper. The goal? It had to be safe, flexible, and dishwasher-safe.
We narrowed the material options to food-grade silicone. Here’s why:
- Heat resistance up to 230°C
- Non-toxic and BPA-free, meeting FDA standards
- Soft touch for safe handling of hot items
The result? A durable, sleek product that delighted both chefs and everyday users. By testing prototypes using various silicone grades, we helped the client minimize risk and speed up time-to-market.
Sustainability in Material Selection
Eco-friendly materials are no longer a niche—they’re fast becoming the standard. But sustainability isn’t just about using green materials. It’s about designing smarter.
Sustainable Material Tips
- Use recycled content where possible (recycled PET, ocean plastics)
- Reduce material volume with efficient designs (thinner walls, hollow structures)
- Design for disassembly to improve recyclability
- Choose renewable sources like bamboo or PLA bioplastics
At Shark Design, we encourage clients to test low-impact materials without compromising on performance. With more options on the market today, choosing sustainable doesn’t mean choosing weak.
Conclusion
Choosing the right material is part science, part strategy, and a whole lot of trial and testing. Whether you’re designing for durability, sustainability, or cost-efficiency, your material selection will impact everything—from how your product performs to how it’s perceived.
At Shark Design, we guide clients through material selection by evaluating function, cost, compliance, and brand alignment. We believe in testing early, prototyping smart, and always keeping the end user in mind.
Struggling to decide? Let’s prototype and test materials for your product—reach out today and turn your idea into something truly built to last.
