Ethan Clarke
Polycarbonate is one of the oldest known polymers, discovered in 1898 by Alfred Einhorn at the University of Munich. It is a highly versatile, mid-priced thermoplastic with excellent impact strength, durability, stability, and clarity. It is commonly used in various industries, including automotive, aerospace, medical, electrical, and telecommunications. Machining polycarbonate is considered an efficient and cost-effective manufacturing process, but is it easy to machine? Polycarbonate has good machinability and is easier to cut compared to metals, but it has some challenges, such as stress cracking and the need for specific coolants and tools.
| Characteristics | Values |
|---|---|
| Machinability | Easy to machine, mold, and thermoform |
| Durability | High impact strength |
| Stability | Good dimensional stability, good thermal stability |
| Clarity | Transparent to visible light |
| Cost | Mid-price range |
| Weight | Lightweight |
| Electrical properties | Good |
| Tensile strength | Higher than Acetal at temperatures over 140°F (60°C) |
| Dielectric strength | Good |
| UV resistance | Good |
| Temperature resistance | Higher than acrylic |
| Chemical resistance | Poor |
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What You'll Learn
Polycarbonate is a tough, impact-resistant plastic
Polycarbonate is known for its durability, stability, and clarity. It has good electrical properties, high impact resistance, and can withstand extreme temperatures. Due to its amorphous nature and low crystallinity, polycarbonate is highly transparent to visible light, with better light transmission than many types of glass. It also has good thermal stability, with a thermal resistance of up to 135°C.
Polycarbonate is considered a good material for machining. It is easily machined, moulded, and thermoformed. The machining process involves removing material from a workpiece to create the desired shape, and it is often automated and computer-operated. Polycarbonate has good machinability, allowing close tolerances without great difficulty. However, it is important to use sharp, uncoated tools and avoid certain coolants, as polycarbonate can absorb coolant and discolour with long exposure to fluids.
Polycarbonate is a mid-priced thermoplastic, making it a popular choice for a wide range of applications. It is lightweight, precise, and has better build quality than metal parts. Polycarbonate can also be cold-bent like metal without problems, although it has considerable springback. Overall, machining polycarbonate is an effective and efficient way to produce plastic parts in most industries.
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It is more machinable than acrylic
Polycarbonate is more machinable than acrylic. Polycarbonate is one of the oldest known polymers, discovered in 1898 by Alfred Einhorn at the University of Munich. It is a tough, impact-resistant material with excellent strength, making it ideal for applications requiring high stress or impact resistance. It is commonly used in automotive components, electrical applications, and safety equipment.
Acrylic, on the other hand, is a relatively brittle plastic with poor resistance to impact. It has a low melting point, which means that a lower cutting feed rate must be used during machining to prevent excessive heat buildup and potential ruin of the product. Acrylic is more susceptible to cracking and chipping than polycarbonate, making it slightly more difficult to machine. It is necessary to use a sharp cutting tool with acrylic to obtain a smooth surface finish, as it is not as heat resistant as polycarbonate.
Polycarbonate's higher temperature resistance allows for more aggressive machining strategies, potentially saving time and money. It is less likely to chip than acrylic and has excellent dimensional stability. Polycarbonate can also be cold-bent like metal without problems, whereas acrylic is impossible to bend in this way.
In terms of optical clarity, acrylic outperforms polycarbonate with 92% light transmission compared to 88%. Acrylic is also naturally resistant to scratches, whereas polycarbonate is more prone to scratching and requires a protective coating or sheet.
Despite these differences, both acrylic and polycarbonate are frequently used in clear plastic applications and offer distinct advantages and disadvantages depending on the specific requirements of a project.
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It is used in CNC milling
Polycarbonate is a popular choice for CNC milling because it is easy to machine and has excellent mechanical properties, including good impact strength, hardness, toughness, and high-temperature resistance. It is also lightweight and highly transparent, making it a great alternative to glass. CNC milling polycarbonate allows for the creation of complex shapes with a better edge finish than sawing.
When milling polycarbonate, it is important to use the correct tool for the specific cutting application and the thickness of the material. For example, a circular saw with a fine-tooth blade can be used for straight cuts in sheets up to 1/4 inch thick, while a jigsaw with a fine-tooth blade is suitable for curved or intricate cuts in sheets up to 1/2 inch thick. To prevent cracking or melting, always use low speed and light pressure when milling polycarbonate.
Before milling, it is crucial to secure the polycarbonate sheet firmly to a solid surface to prevent vibrations. For thicker sheets, milling should be done in several steps to achieve a clean edge finish. It is also important to use sharp cutting bits to limit friction and prevent the plastic from melting due to heat buildup. Applying cutting fluids or coolants can also help mitigate heat buildup and extract chips.
Polycarbonate CNC milling is commonly used in various industries, including aerospace, automotive, electronics, and consumer goods. It is suitable for creating precision plastic parts with standard cutting tools and offers custom PC parts with tight tolerances and superior surface finishes.
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It is a cost-effective manufacturing process
Polycarbonate is a cost-effective manufacturing process due to its versatility, durability, and ease of machining. It is a popular choice for a wide range of applications, including automotive, aerospace, medical, and electrical industries.
Polycarbonate is a mid-priced thermoplastic, making it a cost-effective option for manufacturers. Its durability, impact strength, and thermal stability contribute to its cost-effectiveness. Polycarbonate can withstand high temperatures, making it suitable for applications where extreme conditions are present. Additionally, its electrical properties, such as good dielectric strength, make it a versatile choice for electrical and electronic applications.
The ease of machining polycarbonate also contributes to its cost-effectiveness. It is easier to cut compared to metals, requiring less strength from cutting tools. This results in reduced tooling costs and faster production times. The machining process is mostly automated, with computer-controlled annealing ovens ensuring precision and quality.
Polycarbonate's excellent processability further enhances its cost-effectiveness. It can be cold-bent, moulded, and thermoformed, allowing manufacturers to create complex components with close tolerances. The ability to produce precise replicas of critical designs quickly and in large numbers makes it a favourite among buyers and manufacturers.
However, it is important to note that machining polycarbonate does have some challenges. It is prone to stress cracking, especially when exposed to certain hydrocarbons and coolants. Proper selection of coolants, such as non-aromatic, water-soluble options, is crucial to prevent cracking and extend tool life. Additionally, polycarbonate's tendency to scratch easily may require a secondary polishing process to regain optical clarity.
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Polycarbonate is a good alternative to metal parts
Polycarbonate is commonly used in industries such as safety equipment, optics, automotive, and electrical and electronic components due to its well-rounded mechanical properties. In optics, polycarbonate is used in eyeglass lenses and camera lenses due to its optical clarity and lightweight nature. In the electrical and electronic components industry, polycarbonate is used in electrical insulators, connectors, and LED light covers due to its electrical insulating properties.
Polycarbonate is also a good alternative to metal parts because of its ease of machining. It is easily machined, molded, and thermoformed, making it a versatile material for various applications. Polycarbonate rod and plate, in particular, are easy to machine and have excellent dimensional stability. However, it is important to note that polycarbonate is prone to stress cracking and premature part failure when placed under high heat and tensile load. Therefore, annealing is crucial to achieving quality, precision-machined parts from the stock shape.
Polycarbonate also has advantages over metal in certain applications, such as in the case of phone and electronic device back covers. Polycarbonate provides durability against shattering, bending, and scratching, shock absorption, low manufacturing costs, and no interference with radio signals or wireless charging, which are not offered by metal.
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Frequently asked questions
Yes, polycarbonate is a mid-priced thermoplastic that is easily machined, moulded, and thermoformed. It is a popular choice for a wide range of applications due to its favourable properties.
Machining polycarbonate is considered one of the best ways to get a plastic part in most industries. It is a cost-efficient and effective way to produce replicas of any critical design in large quantities quickly. It is also lightweight, has high precision, and better build quality than metal parts.
Machining polycarbonate can be expensive. It is also prone to stress cracking and premature part failure when placed under high heat and tensile load.
It is recommended to use non-aromatic, water-soluble coolants for ideal surface finishes and close tolerances. Using computer-controlled annealing ovens can also help reduce the chances of stress cracking.
