Polycarbonate vs Acrylic: Which Plastic Sheet is Best for Your Project?
A comprehensive comparison to help you choose between Lexan polycarbonate and acrylic (Plexiglass) for your next project.
Quick Comparison: Polycarbonate vs Acrylic
| Property | Polycarbonate | Acrylic | Winner |
|---|---|---|---|
| Impact Resistance | 200x stronger than glass | 17x stronger than glass | Polycarbonate |
| Optical Clarity | 88% light transmission | 92% light transmission | Acrylic |
| Scratch Resistance | Moderate (can be coated) | Good | Acrylic |
| UV Resistance | Excellent (with coating) | Good (yellows over time) | Polycarbonate |
| Temperature Range | -40°C to 120°C | -30°C to 80°C | Polycarbonate |
| Price | Higher | Lower | Acrylic |
Understanding the Difference
Polycarbonate (brand names: Lexan, Makrolon) and acrylic (brand names: Plexiglass, Lucite) are both clear thermoplastics that can replace glass, but they have very different properties that make each better suited for specific applications.
When to Choose Polycarbonate
Choose polycarbonate sheets when you need:
- Maximum impact resistance: Security glazing, machine guards, protective barriers
- Outdoor roofing: Patio covers, pergolas, carports, greenhouses
- Extreme temperatures: Applications with high heat or cold exposure
- Safety-critical applications: Where breakage could cause injury
When to Choose Acrylic
Choose acrylic when you need:
- Maximum clarity: Display cases, picture frames, retail fixtures
- Scratch resistance: Frequently touched surfaces
- Lower cost: Budget-conscious projects where impact isn't a concern
- Easy fabrication: Detailed cuts, drilling, and shaping
Choosing the Right Thickness
Both materials are available in various thicknesses. For polycarbonate, we recommend:
- 3mm: Light-duty applications, small projects, interior use
- 6mm: Standard roofing, greenhouse glazing, machine guards
- 10mm+: Heavy-duty security applications, high-impact areas
Cost Comparison
Acrylic is generally 30-40% less expensive than polycarbonate of the same thickness. However, polycarbonate's superior durability often makes it more cost-effective long-term for outdoor and high-impact applications where replacement would be needed more frequently with acrylic.
Frequently Asked Questions
Is polycarbonate stronger than acrylic?
Yes, polycarbonate is approximately 200 times stronger than glass and 30 times stronger than acrylic. It's virtually unbreakable and is used in bulletproof glass, safety goggles, and high-impact applications.
Which is clearer, polycarbonate or acrylic?
Acrylic has slightly better optical clarity (92% light transmission vs 88% for polycarbonate) and is more resistant to scratching. However, for most applications the difference is negligible.
Is polycarbonate or acrylic better for outdoor use?
Both can be used outdoors, but polycarbonate with UV coating is generally better for high-impact areas like roofing. Acrylic is better for signage and applications where scratch resistance and clarity are priorities.
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