What’s the Difference Between Plastic and Metal Treadles?

Before getting into strength, weight, or appearance, the best place to start is the environment. Is this switch going in a lab? A factory? Under a surgical table?

Where the switch is placed usually tells you a lot about what it needs to handle.  So, when it comes time to replace that footswitch, it has to go through the OEM to ensure you’re getting the version that was made specifically for that machine.

If a switch is used in a heavy-duty industrial setting where tools or equipment might be dropped, metal is typically the safer choice because it can take more abuse. On the other hand, if the switch is used in a light-duty application where it is not exposed to constant impact or heavy materials, plastic can work just as well and may be more cost-effective.

It is also important to think about what the treadle will be exposed to over time. Chemicals and debris changes can affect plastic differently than metal. For example, in a lab where cleaning agents are used daily, plastic may degrade faster than a metal treadle.

Plastic and metal each have their advantages, but they show up in very different ways.

Plastic treadles provide natural electrical insulation, which can add another layer of safety in certain applications. They also maintain their color longer because the pigment is built into the material. Metal treadles are painted or powder coated, which means the finish can wear away after years of use.

Metal treadles, however, are known for their strength. They handle more impact and are often the better choice in environments where the switch may be exposed to rough handling or dropping objects. While plastic treadles can perform well in controlled settings, metal tends to excel where durability is a top priority.

Cost also influences the decision. As industries have become more price conscious, plastic treadles are now being used more often, especially in applications where heavy abuse is not expected.

Metal treadles are heavier, which often works in their favor. That added weight helps keep the switch stable on the floor and prevents sliding during use.

Plastic treadles are lighter, which can be beneficial in portable setups, but they may flex slightly under pressure, especially at the edges. While this flex is usually minimal and does not impact performance for most users, it is worth considering if precision is important.

When it comes to customization, metal is typically easier and more cost effective for custom colors since many powder coaters keep popular colors in stock. Plastic often requires a separate molding setup and larger material orders, which can make it more expensive for small runs.

Plastic treadles are generally less expensive than metal, which makes them appealing for cost-sensitive projects. However, price is only one piece of the decision.

For larger volume orders that require a custom color, plastic may be the better value because the setup costs for molding can be spread across the quantity. For smaller runs, metal is often more practical because custom powder coating is less expensive in low volumes.

Metal usually has the advantage in durability. It can withstand more impact, while plastic performs well in environments where heavy abuse is unlikely. Failures caused by the material choice are uncommon, but they can happen. For example, dropping a heavy object on a plastic treadle may damage it, while a metal treadle would likely remain intact.

Both materials require little maintenance. Over time, you might see paint wearing off a metal treadle or slight flexing in a plastic one, but in most cases, both will last for years if used in the right environment.

If you are trying to decide between plastic and metal, start with what matters most to your application. Think about the environment where it will be used, the level of wear it will experience, and whether cost, strength, or appearance is your top priority.

Plastic can be an excellent choice for light-duty environments where cost matters and the switch will not be exposed to harsh conditions. Metal, however, is the better option for industrial spaces and other demanding applications where durability is critical.

There is no single answer that works for every situation. But if you look at how these factors apply to your setup, the right choice usually becomes clear.

Choosing between plastic and metal treadles does not need to be complicated. It depends on your application, your environment, and what matters most for long-term performance.

If you are not sure which direction to go, we can help you figure it out. Send us the details of your setup and we will walk through the options with you.

Visit our Learning Center for more blogs that explain the key decisions behind foot switch design. Whether you are looking for guidance on materials or environmental considerations, you will find resources to help you choose the right solution.

Date Uploaded 09/02/25

In collaboration with Christian Smutnick (Applications Engineer) and Dave Drouin (Applications Engineer)