Polycarbonate (PC) Parts Manufacturing

High-precision Polycarbonate component manufacturing via 5-Axis CNC Machining, Vapor Polishing, and Precision Injection Molding. Delivering optical clarity, glass-like transparency, extreme impact resistance, and tight tolerances down to ±0.02 mm

✅ All Design Uploads Are Secure & Confidential

Polycarbonate (PC) Grade Specifications & Selection

Compare optical transparency, impact toughness, and glass-fiber reinforcement options across clear and structural PC grades.

Technical Property	Optical Clear PC (Standard)	PC + 20% GF (Reinforced)	Flame-Retardant PC (UL94 V-0)
Light Transmittance	88 – 90% (Glass-like Clear)	Translucent / Opaque	Translucent / Opaque
Density	1.20 g/cm³	1.35 g/cm³	1.22 g/cm³
Tensile Strength (Yield)	60 – 70 MPa	95 – 110 MPa	65 – 75 MPa
Heat Deflection Temp (HDT)	130 – 140 °C (266–284 °F)	140 – 145 °C	130 – 135 °C
Izod Impact Strength	Ultra-High (Unbreakable)	High Stiffness / Moderate Impact	High Impact
Flammability Rating	UL94 V-2 / HB	UL94 V-1 / V-0	UL94 V-0 (Self-Extinguishing)
Primary Application	Clear safety shields, lenses, light pipes	Rigid electronic frames, pump bodies	Electrical switch boxes, EV chargers

Surface Finishing Options for Polycarbonate Parts

From optical-grade crystal clarity to hard-coat scratch protection and UV-resistant treatments.

As-Machined (Translucent)

Raw finish directly from CNC milling. Produces a frosted, semi-translucent surface with faint cutter tool lines, suitable for internal light diffusers and structural brackets.

Vapor Polishing (Optically Clear)

Specialized solvent vapor process that melts micro-ridges on machined PC surfaces, transforming translucent parts into 100% glass-like transparent components without changing tight dimensions.

Mechanical Diamond Polishing

Multi-step abrasive sanding and diamond paste polishing designed for flat, accessible PC windows, sight glasses, and optical lenses to achieve high light transmission.

Hard Coating (Anti-Scratch)

Applies a transparent hard silicone coating over clear PC parts, increasing surface pencil hardness up to 2H–3H to prevent fingernail scratches and abrasive wear.

UV-Resistant Protective Lacquer

Applies a clear UV-blocking topcoat over Polycarbonate parts, preventing optical yellowing, haze, and embrittlement caused by long-term outdoor sunlight exposure.

Bead Blasting (Satin Frosted)

Uses fine abrasives to produce a uniform satin frosted texture. Ideal for LED light diffuser covers that eliminate glare and hot-spot light points.

Advantages and Considerations of Polycarbonate Manufacturing

Polycarbonate is celebrated for combining optical transparency with bulletproof-level impact resistance.

✓

Advantages of Polycarbonate (PC)

Virtually Unbreakable Impact Toughness: Exhibits extreme impact strength (up to 250 times stronger than glass and 30 times stronger than acrylic), resisting accidental drops and heavy mechanical impacts without shattering.
High Light Transmittance & Optical Clarity: Offers up to 89% light transmission in transparent grades, making it the premier choice for clear safety windows, sight gauges, and lighting covers.
High Heat Resistance (HDT ~135°C): Maintains structural dimensional stability at elevated temperatures compared to standard plastics like ABS or PMMA.
Good Electrical Insulation & Flame Retardancy: Inherent dielectric strength and self-extinguishing flame properties (UL94 V-0 options) make it ideal for electrical housings.

Considerations & Limitations

Susceptibility to Surface Scratches: Softer surface hardness than glass or PMMA makes clear PC prone to fine hairline scratches without protective hard-coat finishes.
Sensitivity to Solvents & Stress Cracking: Can suffer chemical crazing or stress cracking when exposed to strong organic solvents, esters, or alkalis.
UV Yellowing Over Time: Untreated clear PC yellow-tint and lose clarity under long-term direct sunlight. *(Solution: Use UV-stabilized PC resin or clear UV protective coating)*.

PC Parts Manufacturing FAQs

1. How do you make CNC machined PC parts completely crystal clear?

CNC milling leaves a cloudy/frosted surface on clear Polycarbonate. We apply Vapor Polishing (using specialized chemical solvent vapor to smooth surface micro-ridges) or multi-step hand sanding with diamond polishing compounds to restore 100% optical glass-like transparency.

2. What is the difference between Polycarbonate (PC) and Acrylic (PMMA)?

Polycarbonate (PC): Focuses on extreme impact resistance (virtually unbreakable), higher heat deflection (135°C), and flexibility, making it ideal for safety guards and structural covers.
Acrylic (PMMA): Focuses on higher scratch resistance, slightly superior optical clarity, lower cost, and easier flame polishing, ideal for display panels.

3. Can Polycarbonate parts be used in high-temperature or flame-retardant electrical devices?

Yes! Polycarbonate has a heat deflection temperature of ~135°C. We also offer specialized UL94 V-0 flame-retardant PC grades that self-extinguish within seconds after exposure to open flames, making them mandatory for EV charger enclosures and high-voltage junction boxes.

4. How do you prevent clear PC components from scratching during assembly and transit?

Raw PC is susceptible to fine hairline scratches. We offer Anti-Scratch Hard Coating (2H–3H hardness) and ship clear parts wrapped in protective peelable PE film or individual anti-static bubble packaging to ensure defect-free optical surfaces upon arrival.

5. What 3D/CAD file formats do you accept for an instant PC parts quote?

Please upload 3D CAD files in STEP (.stp / .step) or IGES (.igs) format. For clear optical transparency callouts, thread locations, or anti-scratch coating specs, please attach a 2D drawing in PDF or DWG format.