Chloe Zhang
Polycarbonate plastic, also known by the brand names Makrolon and Lexan, is a strong, stiff, hard, tough, transparent engineering thermoplastic. It is used in a variety of applications, including automotive, construction, and electrical and electronics (E&E). The density of polycarbonate plastic is typically expressed in grams per cubic centimeter (g/cm3) or kilograms per cubic meter (kg/m3). Density is important when selecting a plastic for a specific application, as it affects the performance, cost, and sustainability of the product. Polycarbonate plastic has a density that is higher than that of acrylic but lower than that of ABS. Now, let's delve into the specifics of polycarbonate's density and how it compares to other materials.
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What You'll Learn
Polycarbonate is used in the construction industry
Polycarbonate is a versatile material with many applications in the construction industry. It is a type of thermoplastic polymer, strong, tough, and easily worked, moulded, and thermoformed. It is the second-largest consumer of polycarbonates after the automotive industry.
Polycarbonate is also used in security applications, such as prisons, guard booths, bank teller shields, convenience stores, hurricane shutters, and hockey rink surrounds. Its impact strength makes it an excellent choice for blast and bullet-resistant glazing. Polycarbonate is also used in exterior elements for LED lighting due to its durability and crystal-like clarity.
Polycarbonate can be formed into a variety of complex shapes using thermoforming, a heat-based thermoplastic shaping technique. It can also be cold-line bent, similar to metal. Polycarbonate is available in a wide range of thicknesses, structural strengths, and configurations, making it a versatile material for the construction industry.
Polycarbonate has a glass transition temperature of about 147 °C (297 °F), above which it softens and flows. Tools must be held at high temperatures, generally above 80 °C (176 °F), to make strain-free and stress-free products. The toughest grades of polycarbonate have the highest molecular mass but are more difficult to process.
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It is also used in 3D FDM printing
Polycarbonate plastic is a versatile material with many applications, including 3D FDM printing. FDM stands for Fused Deposition Modelling, which is an additive manufacturing process that creates parts by extruding plastic filament through a heated nozzle. This process builds up layers of plastic to create a three-dimensional object.
Polycarbonate is a thermoplastic polymer that exhibits excellent strength, toughness, and impact resistance compared to other commodity plastics used in 3D printing, such as PET and PLA. Its strength and toughness make it ideal for creating functional parts for end-use applications, such as automotive components, that require high durability. For example, a replacement bypass pipe was 3D printed out of polycarbonate and used to repair a leaking heater core in a Mustang 5.0 project car.
Polycarbonate's optical clarity and transparency also make it suitable for transparent prints with aesthetic and functional uses. Additionally, it can undergo large plastic deformations before cracking, making it useful for load-bearing parts. Its electrical insulation properties further expand its applicability in electrical components and hardware.
However, there are some challenges associated with using polycarbonate in 3D FDM printing. It has a high glass transition temperature of around 147°C, requiring specialised 3D printers that can reach high temperatures for extrusion. The material also tends to warp during printing, demanding good adhesion to the print bed. It is hygroscopic, absorbing humidity, so it must be stored in a dry place to avoid print failures.
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Polycarbonate is used in injection-moulded drinking bottles
Polycarbonate is a versatile material with many attractive processing and physical properties. It is a thermoplastic polymer with carbonate groups in its chemical structure. It has a high impact resistance and can undergo large plastic deformations without cracking or breaking. This makes it ideal for injection moulding, where it is injected in a molten state into a mould at high pressure and temperature to create complex shapes. Injection moulding is a high-volume, high-speed production technique that can create millions of components per year with limited human intervention.
Polycarbonate has a glass transition temperature of about 147 °C (297 °F), above which it softens and flows at about 155 °C (311 °F). This makes it valuable in applications where transparent or electrically non-conductive parts are needed, as it can be processed and formed at room temperature using sheet metal techniques. Its high viscosity means it must be heated to a high temperature and injected quickly to prevent degradation from prolonged exposure to high temperatures.
The use of polycarbonate in injection-moulded drinking bottles has raised concerns due to the presence of Bisphenol A (BPA), a high-production-volume chemical commonly used in its manufacture. Studies have shown that BPA migrates into water stored in polycarbonate bottles, and exposure to boiling water increases the rate of migration by up to 55 times. Human exposure to BPA has potential health risks, and regular consumption of beverages from polycarbonate bottles has been associated with increased urinary BPA concentrations. As a result, "BPA-free" plastics have been developed and are now used in various formulations for drinking bottles.
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It is used in eye protection
Polycarbonate plastic is a lightweight thermoplastic that is highly impact-resistant. It is used extensively in eye protection, such as glasses and safety goggles, due to its durability and ability to protect the eyes from UV light.
Polycarbonate lenses have been widely adopted since their introduction in the 1980s, and they offer several advantages over glass or standard plastic lenses. Firstly, they are thin and lightweight, making them comfortable to wear. They are also sturdy and impact-resistant, making them ideal for safety applications. This impact resistance is a result of polycarbonate's ability to undergo large plastic deformations without cracking or breaking. This property is especially useful in eye protection, as it helps to safeguard the eyes from potential hazards.
Polycarbonate lenses are commonly used in safety goggles, including those worn in industrial settings, sports, and by children. Their durability makes them well-suited for these environments, as they can withstand impacts and provide long-lasting protection. Additionally, their lightweight nature is advantageous for sports eyewear, as it reduces the overall weight on the wearer's face.
Another key benefit of polycarbonate lenses is their built-in UV protection. They effectively shield the eyes from harmful UVA and UVB rays, promoting eye health. This feature is particularly useful for individuals who spend a significant amount of time outdoors, such as in sports or recreational activities. The UV protection offered by polycarbonate lenses eliminates the need for additional coatings, simplifying the lens construction.
While polycarbonate lenses offer numerous advantages, there are also some considerations to keep in mind. One drawback is their tendency to scratch easily due to the softness of the material. This characteristic may require the application of scratch-resistant treatments or coatings to enhance the lens's durability. Additionally, polycarbonate lenses may not be ideal for all prescriptions, and in some cases, other lens materials such as Trivex may provide better visual clarity. Nevertheless, polycarbonate lenses remain a popular choice for eye protection due to their combination of durability, impact resistance, UV protection, and lightweight nature.
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Polycarbonate is used in the automotive industry
Polycarbonate plastic is widely used for its impact resistance, transparency, and lightweight nature. Its density is 1.27 grams per cubic centimeter, which is heavier than most plastics but less than half the weight of glass.
In the automotive industry, polycarbonate is used in several applications, including headlamp lenses, interior components, and sunroofs. Its impact resistance and lightweight properties make it ideal for these applications. Polycarbonate is also used in the construction of small motorized vehicles, such as motorcycles, ATVs, golf carts, and small airplanes and helicopters. The windshields of these vehicles are commonly made of polycarbonate due to its strength and lightweight nature.
Polycarbonate is also used in the automotive industry for decorative bezels and optical reflectors. Its smooth surface makes it well-suited for sputter deposition or evaporation deposition of aluminium without the need for a base coat. However, polycarbonate is limited to low-stress applications in the automotive industry due to its susceptibility to stress corrosion cracking when it comes in contact with certain accelerants, such as saltwater and plastisol.
Polycarbonate can be laminated to create bullet-resistant windows, which are often used in automobiles. Its strength and impact resistance make it ideal for this application, providing protection and security for the occupants of the vehicle. Polycarbonate is also used in the automotive industry for weight reduction, as its strength and lightweight properties can improve fuel efficiency and handling.
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Frequently asked questions
Polycarbonate plastic, also known as Makrolon or Lexan, has a density of 1.27 grams per cubic centimeter.
Polycarbonate is denser than Acrylonitrile Butadiene Styrene (ABS), which has a density of 1.03 grams per cubic centimeter, and Starboard HDPE, which has a density of 0.955 grams per cubic centimeter. However, it is less dense than acrylic sheet, which weighs 1.19 grams per cubic centimeter.
Polycarbonate is much denser than water, which has a density of 1 gram per cubic centimeter, but it is less than half as dense as glass, which typically has a density of 2.53 grams per cubic centimeter.
