POLYCARBONATE (PC)

PC (Polycarbonate), was invented independently in 1953 by two chemists working separately; Dr Hermann Schnell at Bayer in Germany, and Dr Daniel W. Fox at General Electric in the United States. Both discovered methods to produce the polymer almost simultaneously, which lead to the commercialisation of polycarbonate in the late 1950s. Bayer marketed it under the brand name Makrolon, and GE under Lexan – both of which are still well-known polycarbonate trademarks today. 

Examples above include our very own business cards, piping nozzles for cake decorating, magnet rollers for valves, covers for lights, and screens for washroom sensors.

Why choose PC for your injection moulding project?

  • 1. Exceptional Impact Resistance; PC is virtually unbreakable under normal use — it’s around 250 times stronger than glass and far more impact-resistant than acrylic (PMMA). Ideal for products that must withstand mechanical stress, vibration, or accidental impact (e.g. protective covers, machine guards, or automotive parts).
  • 2. Excellent Optical Clarity. Polycarbonate offers up to 90% light transmission, making it one of the clearest engineering plastics. Perfect for transparent or translucent parts like lenses, light diffusers, visors, or display panels. It can be tinted or coloured while maintaining clarity.
  • 3. High Heat Resistance - PC maintains its mechanical strength and shape at temperatures up to 120–135 °C (continuous use). Suitable for under-the-hood automotive parts, lighting components, and electronic housings.
  • 4. Dimensional Stability & Precision; Low shrinkage and consistent mould filling allow for tight tolerances and high dimensional accuracy. Ideal for precision-engineered parts, housings, and assemblies that require perfect fit.
  • 5. Excellent electrical insulating properties, even at high temperatures.
  • 7. Resistant to water, dilute acids, and many oils. Grades with UV stabilisers or coatings offer excellent outdoor durability (used for lighting, signage, and glazing).

Overall, PC injection moulding offers many benefits, hence its wide popularity from car headlights to bulletproof glass.

If you have an injection moulding project and are considering using Polycarbonate, please get in touch with our technical team on 01280 706335 for a free consultation!