The Unbreakable Plastic

When ABS simply isn't strong enough, engineers turn to Polycarbonate (PC). Famous for being the primary component in "bulletproof glass," Polycarbonate possesses an impact strength roughly 250 times that of standard glass, and 30 times that of acrylic.

Vacuum Forming Polycarbonate

While incredibly strong, Polycarbonate is notoriously difficult to thermoform correctly due to its hygroscopic nature—it absorbs moisture from the air.

• The Pre-Drying Phase: If a sheet of Polycarbonate is heated in a forming machine without preparation, the trapped moisture will boil, causing thousands of tiny bubbles to form inside the plastic, ruining the part. Therefore, PC must be baked in an industrial dehumidifying oven at 120°C for up to 24 hours immediately prior to forming.
• High Heat Requirements: Polycarbonate has a very high forming temperature window. It requires advanced quartz heaters to reach pliability quickly and evenly.

Applications

Despite the manufacturing challenges, the results are unparalleled. Polycarbonate is the only choice for clear security domes, heavy construction machinery windows, riot shields, and any enclosure that must guarantee absolute protection against blunt force impacts.