Polycarbonate is an impact-resistant plastic used as an alternative to glass where strength, safety and low weight matter. In this guide you get an overview of types, thicknesses, applications and fabrication – so you can choose the right polycarbonate sheet for your project.
What is polycarbonate?
Polycarbonate (abbreviated PC) is a thermoplastic that combines high strength, low weight and good light transmission. The material is often used as a replacement for glass, because it is extremely impact-resistant while remaining flexible in use. You may know it under the brand names Makrolon (Covestro) and Lexan (Sabic) – both are high-quality polycarbonate products. A clear polycarbonate sheet has a light transmission of up to 86–90%, making it suitable for solutions where both strength and transparency are important. At the same time, the material is considerably more resistant to impact and load than traditional materials such as glass and acrylic. Polycarbonate is used in both domestic and industrial solutions – from greenhouses and covers to machine guards and safety screens.
See our range of polycarbonate sheets here
Why choose polycarbonate over glass?
Polycarbonate is around 250 times stronger than ordinary glass and roughly 30 times stronger than toughened glass. Where glass typically shatters on impact, polycarbonate instead absorbs the energy and deforms without breaking. That is why the material is used in everything from riot shields to greenhouses. In practice this means polycarbonate is a considerably safer choice in environments where there is a risk of impact, load or accidents. Polycarbonate also offers a range of practical advantages:
- Weighs only around half as much as glass – easy to handle and install
- High flexibility, allowing it to be formed and cold-bent
- Good resistance to temperature variation (–40°C to +120°C)
- Good insulating performance
This makes the material particularly attractive across construction, industry and DIY projects.
When should you choose polycarbonate?
Polycarbonate is not always the right choice – but in many cases it is the most functional. You should choose polycarbonate in particular if:
- You need high impact resistance and shatter resistance
- Safety is more important than optical perfection
- The material will be used outdoors (always choose UV-protected)
- You want a lightweight alternative to glass
- You need to fabricate, saw or bend the material
For more decorative solutions, where the surface finish matters, acrylic (PLEXIGLASS®) may be a better choice. But in functional, load-bearing environments, polycarbonate is often superior.
Types of polycarbonate and their uses
Polycarbonate comes in several variants, each optimised for specific applications.
Standard polycarbonate (solid)
Standard solid polycarbonate sheets are transparent and extremely impact-resistant. They are typically used indoors in solutions that require safety and durability – for example machine guarding, safety screens and secondary glazing.
See standard polycarbonate
UV-protected polycarbonate
For outdoor use, UV protection is essential. Without it, the material will yellow over time and lose up to 50% of its impact strength over the course of 5–10 years. UV-protected polycarbonate is coated on one or both sides to withstand the sun's rays, giving a considerably longer service life and better durability. This is the type to use for greenhouses, covers, patio roofs and conservatories.
See UV-protected polycarbonate
Scratch-resistant polycarbonate (hard-coated)
Polycarbonate is naturally less scratch-resistant than glass and acrylic. That is why there are variants with an extra-hard surface coating (hard coat) that makes them significantly more resistant to scratches and chemicals. These are typically used in solutions where the surface is visible or subject to daily use – for example in shops, on machinery and in public environments.
See scratch-resistant polycarbonate
Opal and smokey-tinted polycarbonate
Opal sheets (milky white) are used to create diffused light without direct visibility, while smokey-tinted (bronze) sheets soften light and give a more aesthetic appearance. Both are often used for covers and controlled light transmission.
See opal and smokey-tinted polycarbonate
Polycarbonate vs acrylic vs glass
The choice between polycarbonate, acrylic and glass depends on what matters most in your project – strength, finish or optical quality.
Impact strength:
- Polycarbonate: up to 250 times stronger than glass
- Acrylic: 10–20 times stronger than glass
- Glass: reference (weakest)
Weight:
- Polycarbonate: around half that of glass
- Acrylic: around half that of glass
- Glass: heavy
Light transmission:
- Polycarbonate: 86–90%
- Acrylic: 92%
- Glass: 90%
Scratch resistance:
- Polycarbonate: low (unless hard-coated)
- Acrylic: good
- Glass: best
UV resistance:
- Polycarbonate: only with UV coating
- Acrylic: naturally UV-stable
- Glass: naturally UV-stable
Fabrication:
- Polycarbonate: can be sawn, drilled and cold-bent
- Acrylic: can be sawn and drilled, but is brittle
- Glass: must be fabricated professionally
Outdoor service life:
- Polycarbonate: 10–15+ years (UV-protected)
- Acrylic: 15–30 years
- Glass: 30+ years
In professional settings, polycarbonate is almost always chosen when safety is the priority. Acrylic is chosen when finish and clarity are decisive, and glass is chosen when optical quality is non-negotiable.
How long does polycarbonate last?
Service life depends on use, type and installation:
- Indoor use: 20+ years with no loss of properties
- Outdoors without UV protection: 3–5 years before visible yellowing and strength loss
- UV-protected polycarbonate outdoors: typically 10–15 years with guarantee, often longer in practice
With correct installation and maintenance, polycarbonate can last for many years without losing its properties. Most UV-protected polycarbonate sheets are supplied with a 10-year manufacturer's guarantee against yellowing and strength loss.
Which thickness should you choose?
Choice of thickness depends on the project and the load:
- 2–3 mm: light tasks, displays, hobby use and indoor screening
- 4–6 mm: secondary glazing, smaller windows and light protection
- 8–10 mm: covers, conservatories and machine guarding
- 12–15 mm: replacement for safety glass and high loads
- 20+ mm: ballistic protection and extreme loads
The thicker the sheet, the greater the strength, rigidity and sound insulation you get – but also the higher the price and weight. If you are unsure, you are welcome to call +44 1408 910380 for advice.
Examples of real-world use
Polycarbonate is used across a wide range of solutions:
- Industry: machine guarding, splash protection, security windows
- Home: secondary glazing, patio roofs, conservatories, carports
- Garden: greenhouses, pergolas, windbreaks
- Business: safety screens, counter guards, retail fit-outs
- Sport: hockey rink boards, squash walls, protective screens
- Transport: screens and windows in vehicles
What these applications share is the need for high strength and safety combined with transparency and low weight.
How to fabricate polycarbonate
Polycarbonate is easy to fabricate with ordinary tools if you follow the right techniques.
Cutting
Polycarbonate can be cut with a fine-toothed jigsaw or circular saw. It is important to work at moderate speed to avoid heat build-up, which can melt the edge. It helps to use a board as backing and to leave the protective film in place during cutting.
Drilling
Use sharp HSS drill bits and avoid excessive pressure, as this can create stress and cracks in the material. Always drill at least 1.5 x the sheet thickness from the edge. For large holes, a hole saw at low speed is recommended.
Bending
The material can often be cold-bent (typically minimum bend radius = 150 x the sheet thickness). For tighter radii, heating may be necessary. Polycarbonate should be dried at 120°C for 12–24 hours before thermoforming to avoid bubbles.
How to install polycarbonate correctly
Correct installation is decisive for durability:
- Expansion gap: polycarbonate expands around 3 mm per metre with a 50°C temperature change – make sure to allow space
- Screws and fittings: use screws with a sealing washer and always pre-drill holes larger than the screw
- Tightening: avoid clamping the material too tightly – it needs to be able to move
- UV side: always install with the UV coating facing up/outwards (marked with film from the factory)
- Pitch: for roof solutions, a minimum 5° pitch is recommended so water runs off
Incorrect installation is one of the most common causes of problems such as cracks, leaks and a shorter service life.
Common mistakes to avoid
- Choosing polycarbonate without UV protection for outdoor use
- Using sheets that are too thin for the load in question
- Installing without an expansion gap
- Removing the protective film too early during fabrication
- Cleaning with harsh chemicals or scouring pads
- Installing the UV side the wrong way round
These mistakes can reduce service life considerably – from 15 years down to 3–5 years.
Maintaining polycarbonate
Polycarbonate requires minimal maintenance, but correct cleaning is important:
- Use lukewarm water and mild washing-up liquid
- Avoid scouring pads, steel wool and hard brushes
- Use soft microfibre cloths or sponges
- Avoid cleaners containing ammonia, acetone or petrol – they attack the material
- Rinse well afterwards with clean water
This helps preserve the surface and extend service life – especially on hard-coated and UV-protected sheets.
Frequently asked questions
Here are answers to the most common questions about polycarbonate.
Is polycarbonate better than acrylic?
It depends on the use. Polycarbonate is up to 10 times stronger than acrylic and better for safety and outdoor use. Acrylic, on the other hand, is more scratch-resistant, has better light transmission (92% vs 88%) and a nicer finish.
Can polycarbonate be used for greenhouses?
Yes, polycarbonate is one of the most popular materials for greenhouses. Always choose UV-protected polycarbonate to avoid yellowing.
See UV polycarbonate here or see shatter-proof greenhouse glass.
Can you work with polycarbonate yourself?
Yes, polycarbonate is very well suited to DIY projects. It can be sawn, drilled and cold-bent with ordinary tools. We also offer cut-to-size, where we cut the sheets exactly to your measurements.
What is the difference between Makrolon and Lexan?
Makrolon and Lexan are both brand names for polycarbonate. Makrolon is made by Covestro (formerly Bayer), while Lexan is made by Sabic (formerly GE Plastics). Both are high-quality products, and the difference lies mainly in specifications and available variants.
How much does polycarbonate cost?
The price depends on thickness, type (standard, UV, scratch-resistant) and size. See current prices on polycarbonate sheets here – you can also have sheets cut to measure.
Can polycarbonate melt?
Polycarbonate has a mechanical service temperature of up to around 120°C and only melts at around 155°C. It is self-extinguishing and fire class B-s1, d0, making it suitable for environments with heat requirements.
See our range of polycarbonate
See all polycarbonate sheets here
See shatter-proof greenhouse glass
Unsure which type of polycarbonate to choose, or how thick the sheet should be? We are happy to advise – call +44 1408 910380 or write to sales@hm-plastic-shop.co.uk.
