Polycarbonate products offer a great blend of helpful features which include temp resistance, impact resistance and optical properties position polycarbonates in between commodity plastic materials and engineering plastic materials.
Polycarbonate is a very rugged material. Although it features exceptional impact-resistance, it has reduced scratch-resistance and so a hard coating can be applied to polycarbonate eye wear as well as polycarbonate exterior automotive components. The properties associated with polycarbonate are along the lines of those of polymethyl methacrylate (PMMA, acrylic), and yet polycarbonate is actually stronger, it is usable in a wider temperature range and is a bit more expensive. This plastic polymer is highly transparent to visible light and has better light transmission characteristics than many different types of glass.
Polycarbonate has a glass transition temperature of around 150 °C (302 °F), so it softens gradually above this point and flows above about 300°C (572 °F). Tools will have to be held at warm to high temperatures, generally above 80 °C (176 °F) to produce strain- and almost stress free products.
Unlike almost all other thermoplastics, polycarbonate can undergo massive shape changes without breaking or cracking. Due to this fact, it could be processed and formed at room temperature using standard sheet metal techniques, which include forming bends with a brake. For even sharp angle bends with a tight radius, no heating is usually necessary. This makes it useful for prototyping applications where transparent or electrically non-conductive parts are crucial, which cannot be made from sheet metal. Remember that PMMA/Plexiglas, that is similar in looks to polycarbonate, but is brittle and cannot be bent at room temperature.
The light weight of polycarbonate, in contrast to glass, has led to development of electronic display screens that replace glass with polycarbonate, for use in mobile and portable devices. Such displays include newer e-ink as well as LCD screens, though CRT, plasma screen and other LCD technologies generally still require glass for its higher melting temperature and the ability to be etched in finer detail.
Other miscellaneous items produced from Polycarbonate include durable, lightweight luggage, MP3/digital audio player cases, computer cases, high impact riot shields, instrument panels, and blender jars. Many toys and hobby products are made out of polycarbonate parts, e.g. fins, gyro mounts, and flybar locks for use with radio-controlled helicopters.
For use in applications subjected to weathering or UV-radiation, a special surface treatment could be needed. This can be a coating (e.g. for improved abrasion resistance), or as a coextrusion for enhanced weathering resistance.
Bayer Makrolon Polycarbonate is a thermoplastic that starts as a solid plastic material in the form of small pellets. In a manufacturing process called injection molding, the pelletized resin is heated until they melt and become a very thick liquid. The melted liquid polycarbonate is then rapidly pushed into a mold with the empty part being the size and shape of the part you want, compressed under high pressure and cooled to create a finished product , that only takes about a minute to complete.
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