Polycarbonate Sheet (Lexan)
SABIC / Covestro
Overview
Bisphenol-A polycarbonate — the material used for bulletproof glazing, safety helmets, and riot shields. 250× the impact resistance of glass. Machines well but requires sharp tooling and chip evacuation. Yellows slowly with UV unless UV-stabilized grade specified.
Properties
Difficulty
intermediate
Flexibility
rigid
Layer Adhesion
good
Enclosure
no
Heated Bed
no
Dry Storage
no
Pros
- 250× impact resistance of glass — virtually unbreakable
- Excellent heat resistance (continuous 130°C, peak 147°C)
- Good optical clarity (85-90% light transmission)
- Cold-formable — can be bent cold without heating
- Available in UV-stabilized grades
- Excellent electrical insulation
- Laser-cuttable (check grade — no BPA offgassing concern)
- Meets UL94 V-2 standard grades available
Cons
- Scratches more easily than glass
- Yellows with UV without UV stabilizer coating
- Sensitive to ammonia-based cleaners and certain solvents
- Stress cracks at holes without proper drilling technique
- Higher cost than acrylic
- Not as optically clear as acrylic (85% vs 92%)
Best For
- Machine safety guards|Bulletproof and blast-resistant glazing|Electrical enclosures (UL listed grades)|Automotive headlight lenses|Greenhouse glazing|Safety face shields and visors
Avoid For
- Precision optics (lower clarity than acrylic)|Ammonia/solvent-rich environments|Scratch-resistant applications|Applications requiring absolute clarity
Storage
Store with protective film. Avoid ammonia-based cleaners — use isopropyl alcohol or soap and water. Anneal machined parts at 120°C for 1h if stress cracking is a concern. UV-stabilized grade essential for outdoor use.
Brands
Lexan (SABIC)Makrolon (Covestro)Tuffak (Plaskolite)McMaster-Carr