Acrylic vs Polycarbonate: Best Use

When selecting plastic sheets for your project, understanding the differences between polycarbonate (often branded as Lexan) and acrylic (PMMA) is crucial. Both are clear thermoplastics that can replace glass, but they have distinct properties that make them better suited for different uses.

Key Differences at a Glance

Strength & Durability

  • Polycarbonate is extremely strong — about 250 times stronger than glass — and highly impact-resistant.
  • Acrylic is 17 times stronger than glass, but it is more rigid and less impact-resistant than polycarbonate.
  • Polycarbonate is more flexible and less likely to shatter.

Optical Properties

  • Acrylic offers superior clarity with 92-93% light transmission, making it the clearest plastic available.
  • Polycarbonate has slightly lower light transmission (~88-90%) and can yellow faster with UV exposure without special coatings.
  • Acrylic maintains its optical clarity better over time, especially outdoors.

Laser Cutting Compatibility

  • Acrylic is laser-safe and cuts beautifully with CO₂ lasers.
  • Cast acrylic engraves exceptionally well, producing a frosted, high-detail effect.
  • Dark opaque acrylics can sometimes be cut with diode lasers.
  • Polycarbonate is not safe for laser cutting — it releases toxic chlorine gas and results in discoloured, burnt edges.

When to Choose Acrylic

Choose acrylic when:

  • You need laser cutting or engraving.
  • Optical clarity is important.
  • UV resistance matters for outdoor use.
  • Cost efficiency is a factor (acrylic is usually cheaper than polycarbonate).
  • You want clean, polished edges after cutting.

When to Choose Polycarbonate (Lexan)

Choose polycarbonate when:

  • Maximum impact resistance is required.
  • The sheet will experience high stress or heavy use.
  • Heat resistance matters (polycarbonate withstands higher temperatures than acrylic).
  • Flexibility is necessary (polycarbonate can be cold-bent without cracking).

Alternative Cutting Methods for Polycarbonate

Since polycarbonate is not laser-safe, consider these methods:

  • CNC routing
  • Fine-toothed sawing (e.g., using a panel saw, circular saw, or jigsaw)
  • Water jet cutting
  • Scoring and snapping for straight cuts (for thinner sheets)

Final Verdict

For most hobbyists, designers, and fabricators — especially those using laser cutters — acrylic is the better choice due to its clarity, cost, laser compatibility, and ease of fabrication.

However, for high-impact, high-stress applications where strength and durability are critical, polycarbonate may be a better option, even though it cannot be safely laser cut.

Back to blog