Polycarbonate vs Acrylic
Both are clear, amorphous plastics sold as sheet, rod and molding resin, and they look alike on the shelf. Polycarbonate (Lexan, Makrolon) is tough: its notched impact strength is 30 times or more that of acrylic, it bends cold without cracking, and it holds its shape to about 130 °C. Acrylic (PMMA: Plexiglas, Acrylite) is stiffer, harder, clearer and far more resistant to UV and scratching, and it costs less.
The decision usually comes down to what happens if it gets hit. Guards, safety glazing, face shields and anything that must not shatter are polycarbonate. Displays, signage, light guides, lenses and windows where clarity, scratch resistance and outdoor life matter more than impact are acrylic.
| Property | Polycarbonate | Acrylic |
|---|---|---|
| Polymer | Polycarbonate (PC) | Polymethyl methacrylate (PMMA) |
| Trade names | Lexan, Makrolon, Tuffak | Plexiglas, Acrylite, Lucite |
| Density | 1.20 g/cm³ | 1.19 g/cm³ |
| Tensile strength | ~65 MPa (9.5 ksi) | ~70 MPa (10 ksi) |
| Flexural modulus | ~2.3 GPa (340 ksi) | ~3.1 GPa (450 ksi) |
| Izod impact (notched) | ~640-850 J/m (12-16 ft·lb/in) | ~16-21 J/m (0.3-0.4 ft·lb/in) |
| Heat deflection at 1.8 MPa (264 psi) | ~130-140 °C (265-285 °F) | ~95-100 °C (200-212 °F) |
| Light transmission (3 mm) | ~88% | ~92% |
| Hardness | ~Rockwell M70 | ~Rockwell M90-100 |
| UV and weathering | Yellows unless UV-stabilized or coated | Excellent; stays clear outdoors for years |
| Typical uses | Machine guards, safety glazing, face shields, electrical housings | Displays, signage, light guides, lenses, windows, aquariums |
Typical values for the stated conditions. Confirm against the mill certificate and your spec.
Need a Polycarbonate or Acrylic part made?
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Attach a drawing (PDF or STEP) or describe the part; a U.S. shop that fits quotes it.
Decision matrix
A check marks the side with the edge on that dimension.
| Dimension | Polycarbonate | Acrylic |
|---|---|---|
| Machining | Good; tough and does not chip, but edges stay frosted and laser cutting chars | ✓ Good; machines and laser cuts to a clear, polished edge, chips with dull tools |
| Welding | Good; ultrasonic, hot-plate and solvent bonding | Good; solvent cements to near-invisible joints |
| Forming | ✓ Excellent; cold bends on a brake, thermoforms after drying | Fair; must be heated to bend, cracks if bent cold |
| Strength | ✓ Similar tensile; very high impact, will not shatter | Stiffer but brittle; cracks and shatters on impact |
| Corrosion resistance | Fair; attacked by solvents and alkalis, yellows in UV | ✓ Fair; attacked by solvents, excellent UV resistance |
| Finishing | Scratches easily; buy hard-coated sheet for abrasion | ✓ Harder surface; buffs and flame polishes to clarity |
| Material cost | Higher per sheet | ✓ Lower per sheet |
| Availability | Sheet, rod, film and resin, widely stocked | Sheet, rod, tube, block and resin, widely stocked |
Choose Polycarbonate when
- Anything that must not shatter: machine guards, safety glazing, face shields, riot and blast shields
- Parts that are cold bent, drilled near an edge or fastened without cracking
- Service up to about 115-120 °C, or flame-rated housings (UL 94 V-0 grades exist)
- Molded housings with snap fits and bosses that must survive drops
Choose Acrylic when
- Maximum clarity: displays, light guides, lenses, point-of-sale fixtures
- Outdoor exposure without a coating: signs and glazing where impact is not a hazard
- Laser-cut or polished parts where a clear edge matters
- Scratch resistance and lower cost when toughness is not the requirement
Frequently asked questions
- Which is stronger, polycarbonate or acrylic?
- In tension they are about the same, around 65-70 MPa, and acrylic is a little stiffer. In impact polycarbonate is in another league, with 30 times or more the notched Izod strength of acrylic. Acrylic cracks or shatters when struck; polycarbonate dents and bends.
- Is acrylic or polycarbonate more scratch resistant?
- Acrylic. It is harder, and light scratches can be buffed out. Polycarbonate scratches easily, so abrasion-exposed glazing and guards are bought with a hard coat on one or both faces.
- Can you bend polycarbonate without heat?
- Yes, within limits. Thin polycarbonate sheet can be cold bent on a press brake with a generous inside radius, and it can be drilled and punched without cracking. Acrylic must be heated along the bend line and will crack if bent cold.
- Which is clearer, acrylic or polycarbonate?
- Acrylic, at about 92% light transmission against about 88% for polycarbonate, and it stays clear outdoors for years. Standard polycarbonate yellows and hazes in sunlight unless it is UV-stabilized or coated.
