Polycarbonate – also known as acrylic glass or Plexiglas – is a plastic material whose transparency makes it a popular alternative to glass. Polycarbonate was discovered around 1900 by the German chemist Alfred Einhorn, who, after decades of research, did not recognize any commercial potential in the material. Contrary to his assessment, Bayer and General Electric began industrial production of polycarbonate in 1953, paving the way for its successful introduction to the market.

Due to its initially brownish coloration, polycarbonate was first used only for small-scale applications. This changed almost 20 years later when improved production purity enabled the material to achieve its now well-known crystal-clear appearance.

Polycarbonate vs. Glass

Glass

💎 Crystal clear

⚠️ Fragile

🛠️ Difficult to process

⚖️ Heavy

🛡️ Scratch-resistant

💶 Expensive

Polycarbonate

💎 Crystal clear

⚠️ Virtually unbreakable

🛠️ Easy to process

⚖️ Twice as light as glass

🛡️ Scratch-sensitive

💶 Often more affordable

Properties and Applications

Polycarbonate is a thermoplastic polymer and therefore highly heat-resistant. Even extreme temperatures ranging from –40 °C to +120 °C have little effect on the material, making it ideal for use in the food industry, construction sector, and many other demanding applications.

Its exceptional impact resistance makes polycarbonate approximately 250 times more shatter-resistant than glass. As a result, it is widely used in safety glazing, protective eyewear, and even fighter jet cockpit canopies.

In addition, polycarbonate is easy to work with. Drilling, sawing, or cold bending can be performed without causing cracks, even during intensive processing.

In its uncoated form, however, the material is susceptible to scratches. Fortunately, these can often be polished out with ease. The polycarbonate sheets available from METALXACT are also UV-resistant, ensuring they do not yellow when used outdoors.

Upon request, all sheets can be powder coated to provide custom colors and additional surface protection.

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Advantages and Disadvantages of Polycarbonate at a Glance

Advantages

Heat-resistant

Extremely durable

Easy to machine and process

Can be recycled multiple times

Disadvantages

Prone to scratching

Not UV-resistant in its raw state

Energy-intensive production process

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Frequently Asked Questions About Polycarbonate

Is Polycarbonate Weather-Resistant?

Yes, polycarbonate is generally highly weather-resistant. Its outstanding strength makes it resistant to heavy loads and environmental influences. However, when used outdoors, it is important to choose a UV-resistant coated product for maximum durability.

Is Polycarbonate Breakable?

Polycarbonate is considered a shatter-resistant alternative to glass, making concerns about breakage largely unnecessary. Even when subjected to drilling, sawing, and other machining processes, the material remains stable and can be easily cut, drilled, or shaped.

Is Polycarbonate Harmful to Health?

The German Federation for the Environment and Nature Conservation (BUND) classifies Bisphenol A (BPA), a substance associated with polycarbonate, as potentially concerning because it may affect the human hormonal system when released through heating and subsequently absorbed by the body. As a result, polycarbonate is no longer permitted in many food-contact applications such as food packaging and drinking bottles. In most construction applications, however, BPA is present only in harmless quantities.

Our Conclusion

Whether in a fighter jet or in your own backyard, polycarbonate is a versatile material that consistently delivers reliable performance. Thanks to its strength and ease of processing, it is particularly suitable for DIY enthusiasts and beginners, especially when looking for an alternative to glass. We also find the history of this material fascinating—without the work of a German chemist, polycarbonate might never have reached its current importance in both professional and private construction projects.