7 Key Factors to Consider When Choosing Polycarbonate vs. Acrylic

When it comes to replacing conventional glass, alternatives are always around the corner. Polycarbonate and acrylic sheets are often considered top contenders for such purposes. While they’re commonly referred to by their brand names—polycarbonate as "Lexan" and acrylic as "Plexiglass"—they're not entirely interchangeable. Choosing between the two requires a careful evaluation of several factors. At first glance, polycarbonate and acrylic sheets may look alike. Both are transparent, come in various sizes and thicknesses, and can be shaped into custom designs. Technically, they belong to the thermoplastics family, meaning they soften and mold under heat. However, their differences lie in their chemical makeup and how they handle specific conditions. If you're weighing polycarbonate versus acrylic for your next project, here are seven crucial aspects to consider: 1. **Strength**: Polycarbonate is stronger than acrylic, making it more resilient to impact and temperature fluctuations. In fact, polycarbonate is up to 250 times stronger than regular glass, whereas acrylic is about 17 times stronger. 2. **Weight**: Both materials are lighter than glass, reducing the load on structures. Polycarbonate and acrylic sheets of the same size and thickness weigh roughly the same, so weight isn't a deciding factor here. 3. **Transparency**: While both materials appear clear, polycarbonate has a slight tint that may yellow over time due to UV exposure. Acrylic, on the other hand, maintains its clarity better and can be polished to restore its shine if needed. Additionally, acrylic edges can be finely ground to blend seamlessly. 4. **Surface Damage Resistance**: Polycarbonate tends to resist scratches better than acrylic. However, acrylic is more prone to chipping or cracking under extreme force. 5. **Durability Against the Elements**: Acrylic holds up better to UV rays, maintaining its appearance longer without fading or warping. Polycarbonate requires a UV-resistant coating to prevent yellowing but is more resilient to cold weather and doesn’t crack as easily. 6. **Workability**: Polycarbonate is tougher to manipulate but can endure more rigorous fabrication processes. Acrylic, being softer, is easier to cut, drill, and shape, making it a popular choice for intricate designs. 7. **Price**: Acrylic is generally less expensive than polycarbonate due to its lower production costs and simpler fabrication process. However, polycarbonate’s durability makes it a worthwhile long-term investment, especially for high-demand applications. Both materials find their niche in different projects. Polycarbonate excels in high-impact scenarios such as bulletproof windows, roofing, and protective covers. Acrylic, on the other hand, is ideal for decorative items like picture frames, face shields, and display cases. Ultimately, the choice between polycarbonate and acrylic depends on your specific needs. Whether you prioritize strength, durability, or aesthetics, understanding these factors ensures you pick the right material for your project. If you're ready to explore further, feel free to reach out to our team for guidance. *(Editor's Note: This article was originally written in December 2020 and has been updated for accuracy and relevance.)*

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