Plastics have replaced traditional materials such as metal, wood and glass in numerous everyday and specialist uses. If you’re looking for a lightweight, affordable and tough alternative to glass, then polycarbonate sheet has very few rivals. It offers a long list of favourable properties, is quick to produce in the desired shapes, thickness and finish and is recyclable and sustainable.
What is Polycarbonate Sheeting? 
Since its invention in the 1950s, polycarbonate has been used to create countless products. In its essence, this is an incredibly versatile thermoplastic, with very high impact and heat resistance, light weight and clarity.
The unique properties have made it one of the best choices for durable engineering plastics in areas as diverse as construction and manufacturing and a viable alternative to glass and acrylic among other materials. It’s most effective when turned into polycarbonate sheet with efficient production processes such as extrusion that melts raw polycarbonate pellets to produce panels of uniform shape and thickness.
How It’s Made
Polycarbonate is formed by the polymerisation of a monomer called bisphenol A (BPA), combining individual molecules into a long-chain polymer with repeating carbonate groups. It’s these carbonate groups that give the material its unique properties including impact resistance, thermal stability and clarity. Additives, such as flame retardant and UV stabilisers can also be added during the production process to enhance strength and durability.
Different techniques are used to produce polycarbonate, including injection moulding, extrusion and thermoforming. The production of polycarbonate panels includes preparing polycarbonate resin by combining and melting bisphenol A with additives. The molten mixture is then fed through dies which use pressure and heat to shape it to a uniform thickness. Sheets are then passed through a series of rollers or water baths to cool and solidify. The final product assumes its shape and texture when trimmed and surface-finished.
Main Types and Uses 
One of the key benefits of polycarbonate sheeting is the range of different types and the versatility to meet different needs. With its exceptional impact resistance (being 200 times tougher than glass), thermal stability and transparency, clear polycarbonate sheet is seen in numerous products, ranging from riot shields, protective screens and helmets, to commercial signage, bus shelters, skylights and windows.
The material is guaranteed to last against yellowing and hazing even in harsh settings. For outdoor use, consider sheets with UV resistance on both sides and choose glazed polycarbonate sheeting if impact resistance is your main concern in items like machine guards and freight doors.
Coloured and tinted sheets are another popular option. These add visual appeal with a wide spectrum of available colours, the ability to reflect harmful ultraviolet sunlight, and keep areas cool. The materials are impact and weather-resistant, making them ideal for outdoor usage including pool enclosures, patios, greenhouses, carports and more.
Mirrored polycarbonate resembles glass but has the upper hand in impact resistance. It’s widely used in fitness centres, car mirrors and interior trim, correctional facilities, dentistry and cosmetic mirrors, retail signage, displays and more.
Choose abrasion-resistant sheets to enjoy scratch-free surfaces and enhanced durability and variants with anti-static coatings in electronics and semiconductors, the oil and gas industry to prevent static charge and possible accidents and appliances such as dishwashers, bakeware and flooring in the food processing industry.
Other instances include flame-resistant polycarbonate sheets in electrical devices, automotive and aerospace parts and switchgear that are prone to higher temperatures caused by electrical current or open flames. Multiwall polycarbonate is a popular choice for cladding and glazing, greenhouses, roofing, skylights, home décor, shelving, and retail signage. The material consists of layered polycarbonate that exponentially enhances durability and weather and chemical resistance while also providing heat and soundproofing in a single product.
Properties and Key Benefits 
The multitude of favourable mechanical, chemical and physical properties of polycarbonate sheeting make it a low-cost, durable and recyclable replacement for glass and other engineering thermoplastics such as acrylic and polyethylene. The material retains uniformity and rigidity in temperature extremes ranging between -20 to +140 degrees Celsius, is heat resistant up to 135 degrees and exhibits high impact strength preventing cracks or breakage. Related are the good insulation properties that can be further enhanced with additives like flame retardants. The material is also flexible and bendable, allowing it to be bent and moulded in different shapes, such as curved surfaces.
Light transmission is on par with glass, meaning polycarbonate sheeting can be used to retain natural lighting while also providing aesthetic appeal to interiors. For outdoor and usage in harsh environments, choose polycarbonate sheets to shield against the detrimental effect of various acids, bases and solvents. And with UV additives, the thermoplastic allows for 100 per cent protection against harmful UV radiation.
Lastly, being twice as light as glass yet much more durable means polycarbonate can be used in areas where weight savings are crucial, such as automotive and aerospace components and electronics. And let’s not forget, the material is also recyclable, so unused or damaged items made of polycarbonate sheeting can be repurposed, enhancing sustainable practices and lowering costs.
Compared to Other Plastics
Compared to plastics such as acrylic with similar appearance, polycarbonate is stronger, shatterproof (so easier to work with), has higher heat resistance and somewhat better resistance to chemicals. Both materials come in different form factors, can be clear or coloured and are similar in weight. Acrylic has a slight edge in terms of transparency and scratch resistance. Polycarbonate is somewhat more expensive, but the added strength and durability make it a better option in demanding settings.
Compared to engineering plastics such as ABS, polycarbonate has a higher impact, temperature resistance, and improved clarity (compared to the matte finish of ABS). ABS on the other hand is better against a wider range of chemicals, is slightly cheaper and easier to machine and has better inherent UV resistance, without the need for stabilisers.
Similarly, commercial-grade polyvinyl chloride (PVC) sheets can be a low-cost substitute for polycarbonate in everyday uses such as eyewear, electronics and consumer items. The material has lower tensile strength, lower heat and chemical resistance and average insulation properties by comparison.
Sourcing Polycarbonate Sheets
Thickness and colours should be top priorities when buying polycarbonate sheeting. Generally the thicker the material the higher the impact and heat resistance. Thicknesses in single-layer sheets range between 2 and 35mm. Thinner sheets (between 2 and 6mm) are ideal in greenhouse glazing, 10mm is standard in carports and canopies, while thicker variants (25, 32 and 35mm) are used in roofing applications and for thermal efficiency in conservatories.
Colours and transparency are all about aesthetics. Light transmission is understandably better with clear polycarbonate panels, but opaque and opal-tinted sheeting is also popular, offering a balance of privacy, natural light and better cooling characteristics. Source polycarbonate sheets from trusted plastics suppliers in the size you need for the application, and from established brands such as Lexan, Nudec and Makrolon.
