The standard transparent engineering plastic — polycarbonate combines glass-like optical clarity with unbreakable impact resistance (200× stronger than glass). Used for machine guards, safety shields, optical enclosures, and light pipes. Machining requires care: PC is gummy, scratches easily, and cracks at stress concentrations.
89% light transmission and essentially unbreakable under normal impact loads — the go-to material for safety glazing.
−40 to +115 °C continuous; holds dimension and impact resistance across the range.
UL 94 V-0 grades for electrical enclosures and consumer electronics.
| Element | Content |
|---|---|
| Polycarbonate (bisphenol-A) | 100% |
| Common grades | Lexan (GE/Sabic), Makrolon (Covestro), Palsun |
Composition per ASTM D3935. Specific mill test reports (MTR) available on request for production orders.
Solvents (especially acetone, alcohols) cause crazing and cracking under stress. Avoid solvent-based adhesives and cleaners near machined PC parts.
Use polished-flute carbide, positive rake. Dull tools melt the surface and leave haze. Avoid flood coolant — use mist or dry cutting for optical surfaces.
If the application is purely optical (no impact loading), acrylic is cheaper, easier to machine, and clearer. Use PC only when impact resistance is required.
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