Program fit
First articles through production on one steel tool, no MOQ.
Engineering Resin
Polycarbonate (PC): for drop impact, clarity, and tougher housings
Move to PC when ABS or PP cannot deliver the impact strength, heat margin, or optical clarity the product needs. NetProto reviews gate strategy, residual stress, and grade requirements before production.
Why Teams Choose PC
Choose polycarbonate when impact or optics push past commodity resins
PC is not a default housing resin. It is the upgrade path when drop resistance, cracking risk, heat margin, or transparency become product requirements.
Product teams usually arrive at PC after ABS feels too brittle, too soft in heat, or unable to deliver a clear window or protective cover in the same part.
Because clear and cosmetic PC parts amplify gate marks, residual stress, and weld-line visibility, DFM should focus on flow path and appearance class earlier than on a standard opaque ABS cover.
Key traits
NetProto program fit for Polycarbonate
Platform and tooling facts that apply to every resin on this page.
NetProto platform
Instant CAD quoting and DFM feedback before tooling release.
Tooling lead time
Hardened steel tool build in about 10 business days on qualified programs (part complexity dependent).
Common grades
Common Polycarbonate (PC) grades by use case
Pick one of these on the instant quote, or name any other commercial grade in the RFQ notes.
| Use case | Example grade | Typical parts |
|---|---|---|
| General purpose | Chimei PC-110 | Electronics housings, auto warning light shells, consumer enclosures |
| 10% glass fiber | Lexan 500R | Headlamp lenses, safety components, stiff structural parts |
| Flame retardant | Lexan 940A | Electrical enclosures, appliance and industrial housings |
| Clear, low viscosity | Makrolon 2458-550115 | Clear housings and optics for regulated healthcare programs |
| UV stabilized | Makrolon 2407 | Outdoor and UV-exposed clear or tinted parts |
| High flow / thin wall | Chimei PC-122 | Thin wall transparent parts, complex clear molding |
PC Snapshot
Where polycarbonate earns its cost—and where it creates process risk
Compare this PC snapshot against ABS if you are deciding whether the upgrade is justified.
Best PC Fits
Programs that need PC’s toughness or optical performance specifically.
- Clear or tinted covers, light pipes, lenses, and protective windows
- Drop-resistant device housings and impact-critical enclosures
- Electrical covers needing toughness plus dimensional stability
- Parts that outgrow ABS on heat, crack resistance, or optical targets
PC Strengths
Why buyers pay more for polycarbonate versus ABS or PP.
- High impact strength for drop, abuse, and crack-sensitive designs
- Optical clarity options that ABS and PP generally cannot match
- Better heat and toughness margin than many commodity housing resins
- Dimensional stability useful for tighter enclosure and assembly fits
PC Watch-outs
Cost and process risks that should be acknowledged before tooling.
- Higher resin cost than ABS or PP for equivalent part volume
- Gate blush, weld lines, and residual stress are more cosmetic-sensitive
- Poor resistance to some solvents, cleaners, and aggressive chemicals
- Drying, tooling polish, and process control matter more on clear grades
PC Design Focus
Clear-part and impact-housing notes unique to polycarbonate
These are the PC issues that most often change tooling or gate strategy—not generic molding reminders.
Define whether the part is optical-clear, translucent, tinted, or opaque before quoting
Place gates away from critical viewing areas to reduce blush and residual-stress patterns
Avoid sharp internal corners on impact-loaded housings that can initiate cracks
Disclose cleaning chemicals or solvent exposure that can attack PC in service
Call out flame, UV, or regulatory grades early—specialty PC options change both cost and process window
PC Application Map
Polycarbonate use cases and the appearance/impact checks that matter
This map is oriented around optics and toughness, not commodity packaging or wear parts.
| PC use case | Why PC is justified | Critical PC check |
|---|---|---|
| Transparent covers and lenses | Clarity plus toughness in one molded component | Optical grade, polish, and gate vestige location |
| Drop-resistant device housings | Higher crack resistance than standard ABS in many designs | Wall/rib strategy and residual stress risk |
| Protective windows and guards | Visibility with impact durability for safety-facing parts | Scratch, coating, and chemical cleaning exposure |
| Electrical toughness covers | Dimensional stability with elevated mechanical demands | Flame rating, heat rise, and regulatory documentation |
PC vs ABS
Is polycarbonate worth the upgrade from ABS?
Most PC conversations start as an ABS upgrade decision. Use this comparison before locking resin family.
Upgrade to PC when
- Drop or crack resistance exceeds what ABS can reliably provide
- The design needs clear, tinted, or optical surfaces
- Heat margin or dimensional stability is a product requirement
- Warranty risk from brittle failure is higher than resin cost
Stay with ABS when
- The housing is opaque and cosmetic painting/texture is the priority
- Impact and heat targets are moderate and cost sensitive
- You want a wider, more forgiving process window
- Chemical exposure is light and ABS already meets the function
PC Quote Path
How NetProto reviews a polycarbonate project
PC quoting should prioritize optical class, gate strategy, and chemical exposure earlier than a standard opaque housing review.
- 1
Define the performance upgrade
Confirm whether PC is needed for impact, clarity, heat, or a combination of those drivers.
- 2
Set the appearance class
Separate optical-clear surfaces from structural or non-visible areas so tooling and gating can be planned correctly.
- 3
Review stress and gate risk
Check thick sections, weld lines, and gate locations that create blush or residual stress in PC.
- 4
Lock grade and compliance needs
Align on flame, UV, medical/food-contact, or standard grades before final pricing and lead-time assumptions.
RFQ
Ready to quote? Have this information ready
Prepare these details, then upload CAD on the instant quote platform.
Transparency requirement (clear, tinted, or opaque)
UV exposure and outdoor service
Notched impact requirement around corners and holes
Stress cracking risk: chemicals, cleaners, or solvents in contact
Flame performance requirement, as listed in the supplier data
Commercial grade, or the use case to match (10% GF, flame retardant, clear optical, UV stabilized, regulated program)
Expected annual volume (helps cavity and tool planning)
Next step
Upload CAD for an instant quote
Grade not finalized? Note Polycarbonate on the RFQ and attach environment notes.
Compare and explore
Related guides
Pairwise comparisons and sibling material pages.
PC vs acrylic
Impact vs clarity and scratch resistance.
PC vs acrylicABS vs polycarbonate
Housing toughness routing.
ABS vs polycarbonatePC/ABS blend
Lower cost tough housing blend.
PC/ABS blendAcrylic (PMMA)
Clearer, more scratch resistant.
Acrylic (PMMA)Reading a material datasheet
What the TDS (Technical Data Sheet) values mean for a molded part.
Reading a material datasheetSpecify resin grade on an RFQ
How to write grade, color, and fillers so the quote matches the part.
Specify resin grade on an RFQPC FAQ
Polycarbonate questions that change the quote
Focused on ABS upgrades, optical grades, and process sensitivity.
When should I choose polycarbonate over ABS?
Choose PC when impact strength, heat performance, or optical clarity exceed what ABS can reliably deliver. Keep ABS when cost, paintability, and a more forgiving process window matter more than those upgrades.
Does polycarbonate have to be clear?
No. PC is available clear, translucent, tinted, and opaque. If optics matter, specify the viewing surface and finish expectations—clear grades are far more sensitive to gate and polish decisions.
Why do PC parts need more DFM attention?
PC can show residual stress, gate blush, and weld-line visibility, especially on clear or high-cosmetic parts. Geometry and tooling decisions affect both appearance and crack resistance.
What should I send for a PC quote?
CAD, quantity, clarity/color targets, drop or impact expectations, chemical exposure, finish class, and any flame or regulatory grade needs.
What is the minimum order quantity for molded parts at NetProto?
NetProto has no minimum order quantity on molded parts from your production tool. Upload CAD on the instant quote platform to scope tooling and part pricing for your volume.
How do I quote this resin without a final grade selected?
List the resin family on the RFQ, attach environment and compliance notes, and upload CAD. At NetProto, engineers use DFM review to narrow grades before tooling release.
Quote a PC Part
Need DFM feedback before committing to polycarbonate?
If you are upgrading from ABS for impact or optics, upload the CAD and call out the surfaces that must stay clear, tough, or cosmetic-critical.