Polycarbonate / Makrolon / Lexan

Polycarbonates (PC), known by the trademarked names Lexan, Makrolon, Makroclear and others, are a particular group of thermoplastic polymers. They are easily worked, molded, and thermoformed. Because of these properties, polycarbonates find many applications. Polycarbonates do not have a unique resin identification code and are identified as Other, Items made from polycarbonate can contain the precursor monomer bisphenol A (BPA).

Polycarbonate (Makrolon / Lexan) is a transparent thermoplastic sheet material used where impact resistance, flame retardency, good dielectric properties and optical clarity are priorities. Polycarbonate thermoforms well, is easy to paint and bonds well using solvents and adhesives. It also has exceptionally high impact strength over a wide temperature range. Many grades of polycarbonate are available with each providing specific properties for a variety of applications. It can even be FDA approved for food-contact and medical applications. Additional applications are protective shields, architectural glazing, indoor and outdoor signs, skylights, shelves, fixtures, aerospace and mass transit interior surfaces, automobiles and product displays.

Polycarbonate offers all of the clarity and beauty of acrylic with an impact resistance that is unparalleled in glazing materials. Polycarbonate is used in applications such as machine guards and security windows that require the optical clarity and the assurance of safety. Polycarbonate is relatively light weight and is fairly rigid. Polycarbonate is easily sawed, machined, heat formed, cold formed, cemented and painted. Polycarbonates are high molecular weight, amorphous engineering thermoplastics that have exceptionally high-impact strength over a wide temperature range.

Polycarbonate (PC) resins are produced in the U.S. principally by General Electric Co (Lexan) and by Bayer Corp (Makrolon). The Dow Chemical Co has recently become the third producer of polycarbonate resins (Calibre).

Polycarbonates are generally unaffected by greases and oils. However, they are attacked by most aromatic solvents, esters and keytones which cause crazing and cracking in stressed parts. Grades with improved chemical resistance are available and special coatings can be applied to provide additional chemical protection. Makrolon polycarbonate's unique combinations of properties. It is virtually unbreakable, lightweight with glass-like transparency and is impact resistant – even at extremely low temperatures. It has a high dimensional stability and is easily molded, yet has excellent heat resistance with a glass transition temperature of up to 148ºC.

Products made out of polycarbonate boast a long life and allow efficient reusability. Stronger and lighter than glass, polycarbonate also provides energy and CO2 emmision savings. Furthermore, it reduces product losses due to breakage during distribution and use. Most post-production waste is mechanically recycled into “recyclate grade” polycarbonate blends. 

Key Properties

Exceptional Impact Strength

Easily Fabricated

Outstanding Clarity

Flame Retardancy

Wide Temperature Range

Standard Shapes and Forms

Sheet: .030” – 4” thick

Other Forms:  Rod, Tube and Film - see Polycarbonate under Engineering Plastics

Applications

Electronic components

Polycarbonate is mainly used for electronic applications that capitalize on its collective safety features. Being a good electrical insulator and having heat-resistant and flame-retardant properties, it is used in various products associated with electrical and telecommunications hardware. It can also serve as a dielectric in high-stability capacitors.

Construction materials

Polycarbonate sheeting in a greenhouse. The second largest consumer of polycarbonates is the construction industry, e.g. for domelights, flat or curved glazing, and sound walls.

Data storage

CDs and DVDs

A major application of polycarbonate is the production of Compact Discs, DVDs, and Blu-ray Discs. These discs are produced by injection molding polycarbonate into a mold cavity that has on one side a metal stamper containing a negative image of the disc data, while the other mold side is a mirrored surface.

Automotive, aircraft, and security components

In the automotive industry, injection-molded polycarbonate can produce very smooth surfaces that make it well-suited for sputter deposition or evaporation deposition of aluminium without the need for a base-coat.

Niche applications

Polycarbonate, being a versatile material with attractive processing and physical properties, has attracted myriad smaller applications. The use of injection molded drinking bottles, glasses and food containers is common, but the use of BPA in the manufacture of polycarbonate has stirred serious controversy (see Potential hazards in food contact applications), leading to development and use of "BPA-free" plastics in various formulations.

Laboratory safety goggles

Polycarbonate is commonly used in eye protection, as well as in other projectile-resistant viewing and lighting applications that would normally indicate the use of glass, but require much higher impact-resistance.

Medical applications

Many polycarbonate grades are used in medical applications and comply with both ISO 10993-1 and USP Class VI standards (occasionally referred to as PC-ISO). Class VI is the most stringent of the six USP ratings. These grades can be sterilized using steam at 120 °C, gamma radiation, or by the ethylene oxide (EtO) method. However, scientific research indicates possible problems with biocompatibility. Dow Chemical strictly limits all its plastics with regard to medical applications

Phones

Some major smartphone manufacturers use polycarbonate. Nokia has used polycarbonate in their phones starting with the N9's unibody case in 2011. This practice continues with various phones in the Lumia series. Samsung has started using polycarbonate with Galaxy S III's battery cover in 2012. This practice continues with various phones in the Galaxy series. Apple has started using polycarbonate with iPhone 5c's unibody case in 2013.

Grades and Colors

Makrolon AR

Makrolon AR (abrasion-resistant) polycarbonate sheet offers glasslike surface hardness and the impact strength of polycarbonate. With enhanced UV resistance to protect against yellowing and hazing, Makrolon AR provides a longer service life for high-profile architectural glazing, and performs extremely well for other flat applications such as view windows and machine guards in harsh chemical environments. It is also useful for school, hospital and bus shelter glazing.

Makrolon FD

Makrolon FD (food grade) polycarbonate sheet is a clear, non-UV-stabilized sheet which complies with FDA and NSF standard 51 requirements. Close gauge tolerance control combined with high impact strength and heat resistance make Makrolon FD ideally suited for demanding applications in medical equipment as well as food processing environments. Some of those applications are bulk food bins, candy molds, sneeze guards, commercial serving bowls, hospital trays, bassinets, incubators and medical device storage containers.

Makrolon FI

Makrolon FI (flame-inhibiting) polycarbonate sheet is formulated for electrical and electronic device applications. Makrolon FI polycarbonate sheets offer V-0 ratings under the UL 94 test criteria in thicknesses from .060”, and is UV-stabilized in gauges greater than 1/8”. Typical applications include transparent interior aircraft components, switchgear covers, thermoformed equipment housings and electrical devices. Also available is Makrolon LF (Low Flame) which is not certified for use on aircrafts.

Makrolon GP

Makrolon GP (general purpose) is a clear, polished surface, UV-stabilized polycarbonate for use in sign and glazing applications. Offering high performance and economy, this sheet meets or exceeds the physical properties of any product in its class. Typical applications include impact-resistant windows, signage, machine guards, barriers and partitions.

Makrolon MG

Makrolon MG (machine grade) polycarbonate engineering plate is an amorphous thermoplastic material that offers extremely high impact strength, high modulus of elasticity, outstanding dimensional stability and good mechanical and electrical properties.  See our Polycarbonate Machine Grade page for more information.

Makrolon OP

Makrolon OP (optical grade) polycarbonate sheet is a clear, polished surface, UV stabilized sheet for use in premium visual applications. Offering high performance coupled with excellent optical clarity, Makrolon OP polycarbonate sheet meets or exceeds the physical properties of any product in its class. Typical applications include aftermarket automotive parts, military vehicle glazing, laminated security glazing and other demanding applications requiring low distortion with optimal visual quality.

Makrolon SL

Makrolon SL (SunLife) polycarbonate sheet is an enhanced UV-resistant sheet with exceptional weatherability and superior impact strength. Available in clear as well as a variety of colors, SL is the perfect choice for extended service life and resistance to color shift. Makrolon SL polycarbonate sheet and reel is easily thermoformed, fabricated and decorated. Typical applications include skylights, barrel vaults, covered walkways and general glazing.

Makrolon Hygard

Makrolon Hygard, the ultimate security product, was developed to meet the need for a higher performing security glazing material. Makrolon Hygard offers multiple levels of protection with certified containment glazing (CG) and bullet-resistant (BR) material. They both feature hard coated surfaces for exceptional resistance to abrasion and UV degradation. Designed for security installations such as detention and correctional centers, government facilities and banks, Makrolon Hygard is being used increasingly for employee protection in 24-hour gas stations and convenience stores as well as other cash transaction areas.

Polycarbonate / Makrolon / Lexan Pictures