7 Key Factors to Consider When Choosing Polycarbonate vs ...

For every standard material, there's always an alternative. 

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For nearly every standard material, there's always an alternative. 

Polycarbonate and acrylic sheets are frequently used as substitutes for traditional glass. 

Considered 'plastic glass,' both are a suitable substitute for many regular glass applications and offer improved security and public safety. You've probably talked about both materials by their brand names. Polycarbonate sheets are often referred to as 'Lexan,' and acrylic as 'Plexiglass.'

However, these two materials are not fully interchangeable. When comparing polycarbonate and acrylic for your commercial project, it's important to weigh several key factors.

Breaking Down Polycarbonate vs Acrylic

To choose the right glass alternative, it's important to first grasp the key differences between polycarbonate and acrylic.

Appearance and Flexibility

At first glance, polycarbonate and acrylic sheets seem quite similar. Both materials are clear, available in various thicknesses and sizes, and can be shaped into specific forms.

Thermoplastic Family

Technically, both are part of the thermoplastics family, which means they share some general characteristics, like being moldable at certain temperatures.

Key Differences

However, despite these surface similarities, their distinct chemical compositions and manufacturing processes lead to some notable contrasts. Understanding these differences will help you make a more informed decision for your project.

Polycarbonate vs Acrylic: 7 Factors to Consider

When considering one material over the other, here are 7 key factors to evaluate:

1. Strength 
2. Weight
3. Transparency
4. Surface damage resistance 
5. Durability against the elements 
6. Workability 
7. Price  
   
   

1. Strength 

Put up against each other, polycarbonate is stronger than acrylic. Less rigid and able to withstand temperature changes without breaking, polycarbonate sheets are ideal for some of the toughest jobs -- even providing protection against bullets. 

While one is stronger and more durable than the other, both acrylic and polycarbonate sheets are stronger than standard glass. Compared to traditional glass, polycarbonate sheets are up to 250x stronger, while acrylic is only 17x.

2. Weight 

Compared to traditional glass, acrylic and polycarbonate sheets weigh about 50% less. When put against each other, acrylic and polycarbonate sheets with the same dimensions don't tip the scale in one direction or the other. 

3. Transparency 

To the naked eye, polycarbonate and acrylic both appear to boast the same clarity for glass alternatives for windows. 

Upon closer inspection, polycarbonate does have a slight tint to it. When exposed to sunlight over long periods of time, that tint does eventually turn yellow. And it's impossible to restore the material to its original clarity. 

Though only slightly clearer, acrylic does outshine polycarbonates on the appearance front in a few ways. Acrylic is a shinier material and can be polished to maintain its sheen. Should its transparency dull, you can also polish acrylic to restore its original appearance. In addition, an experienced fabricator is able to grind the edges of acrylic pieces to be almost visually nonexistent.

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4. Surface Damage Resistance

In this category, one material isn't better than the other. It comes down to the intended use and the type of surface-level damage each is susceptible to. 

Polycarbonate sheets are more likely to fall victim to scratches that can't be buffed out. On the other hand, acrylics are more apt to chip or even crack when subjected to strong impacts.

5. Durability Against the Elements 

For indoor use, both materials stand up to whatever their intended uses are. It's when the elements enter the equation that things become tricky. 

When installed outdoors, acrylic sheets fare better against exposure to the sun. Because of acrylic's chemical composition, it's resistant to UV rays and doesn't warp or discolor as easily. Polycarbonate sheets, however, need additional protection from the sun's rays -- usually a thin layer of a UV ray-resistant coating is applied to both sides of the material. As we mentioned, they'll also yellow after prolonged exposure to the sun.  

Polycarbonate sheets, however, stand up to the cold much better than acrylic. As a stronger material, polycarbonate sheets do not become as brittle and are less likely to crack.

6. Workability

In comparing polycarbonate vs. acrylic, polycarbonate sheets are easier to work with -- but not in the sense you might think. 

Because polycarbonate sheets are stronger, they are better suited for fabrication than acrylics. Whether cut, drilled, or shaped, polycarbonate is less likely to break, though it does take more effort and skill to fabricate. 

Acrylic's comparative weakness, however, does make the material easier to form. In simplest terms, acrylic sheets won't lose integrity or strength after being heated and molded into a shape.

7. Price

In comparing polycarbonate vs. acrylic cost, the latter is the cheaper alternative. 

Because of its strength, durability, and the extra effort required during fabrication, polycarbonate costs more. Those factors contributing to its higher cost make it a better long-term investment. 

Though easier to work with, acrylic is more prone to breaking. It's a cheaper alternative to glass that is easier on your wallet to replace. 

Applications for Both Glass Alternatives 

Due to their similarities, both polycarbonate and acrylic can be used for a variety of applications, such as windows, partitions, and sneeze guards.

Polycarbonate Strength

Polycarbonate sheets, being the stronger of the two, are particularly well-suited for high-impact or heavy-duty uses, including:

• Bulletproof windows
• Roofing
• Greenhouses
• Windshields for outdoor equipment like four-wheelers, tractors, and logging machinery
• Windows that provide sound dampening and thermal protection
• Additional protection against blunt impacts, such as coverings for glass windows in businesses
  
  

Acrylic Versatility

While still durable and easier to shape, acrylic is a great glass alternative for applications like:

• Display cases
• Picture frames
• Face shields

Deciding Polycarbonate vs. Acrylic for Your Project 

Though not the same as glass, polycarbonate and acrylic sheets do the same jobs and offer enhanced strength and protection. 

In considering which glass alternative is proper for your project, evaluate these seven factors with your intended use to make the best selection possible. 

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(Editor's note: This article was originally published in December and was recently updated.)