What is Polycarbonate (PC)?
2025/11/6
Polycarbonate (PC) is a high-performance, transparent thermoplastic widely used for its combination of toughness, optical clarity, and flame resistance. It performs reliably in temperatures from −40 °C to 120 °C and is suitable for indoor and outdoor applications. PC is ideal for protective covers, shields, and components that need both visibility and impact resistance, and it can be shaped via injection molding, extrusion, vacuum forming, blow molding, or 3D printing.
Key Advantages
Exceptional Impact Strength
PC is one of the toughest plastics available. It is five times stronger than ABS, ten times stronger than PVC, and fifty times stronger than acrylic or PE. It can withstand hammer blows and is a core material in bullet-resistant glass.
High Transparency
PC transmits 80–90% of visible light, offering near-glass clarity while combining toughness that acrylic alone cannot provide.
Dimensional Stability
PC's low shrinkage during molding and minimal water absorption provide excellent dimensional accuracy.
Flame resistance
PC is flame-retardant and resists continuous burning if ignited, improving safety for many applications.
Weather durability
PC withstands UV exposure and outdoor conditions better than many plastics, making it suitable for long-lasting exterior components.
Important Usage Precautions
Avoid exposure to solvents and surfactants. Organic solvents, alkaline cleaners, or certain glass coatings can cause stress cracking, warping, or surface damage.
Surface susceptibility to scratching. PC scratches more easily than acrylic. Use gentle cleaning methods and avoid abrasive tools to maintain clarity.
Applications
Polycarbonate’s combination of transparency, toughness, and dimensional stability makes it ideal for both consumer and industrial products, including:
Eyeglass lenses
DVD and optical disc substrates
Safety windows and partitions in schools and childcare facilities
Smartphone camera lenses, casings, and covers
Portable electronics exposed to shocks or temperature changes
Exterior parts requiring durability and design flexibility
Additional applications include:
Motorcycle windscreens and helmet visors
Riot shields
Carport and canopy roofing
Highway sound barriers
Automotive headlights
LED light guides
A Brief History
Bayer AG of West Germany first sold PC as a film material in 1959, and as a molding material the same year. Teijin Chemical Co., Ltd. of Japan began production in 1960. Today, global production is around 300,000 tons annually, supplied by multiple manufacturers.
How PC Is Manufactured
PC is produced by reacting bisphenol A with phosgene, creating the repeating carbonate (-O-(C=O)-O-) groups that give PC its transparency. Industrial production methods include:
Direct reaction of bisphenol A and phosgene
Interfacial polycondensation, reacting bisphenol A in an alkaline aqueous solution with phosgene in methylene chloride
Ester exchange (solution process), reacting bisphenol A with diphenyl carbonate under heat and reduced pressure for narrower molecular weight distribution
PC can also be blended with glass fibers or ABS to enhance mechanical properties. Along with acrylic, PC is sometimes called “organic glass” due to its clarity.
Step Up Your Project with Yumoto Electric
Yumoto Electric delivers high-quality components fast, worldwide. We provide precision machining for a wide range of engineering plastics, including PEEK, PPS, MC Nylon, and POM.
If you’re unsure about material selection or machining methods, we offer complimentary consultations to help optimize your design and production. For any questions, please feel free to contact us.
