Acrylic applications: aquariums, skylight domes, retail fixtures.
Polycarbonate and acrylic are two of the most widely used transparent plastics, often chosen as lightweight, shatter-resistant alternatives to glass. A new guide from Interstate Plastics highlights how the two materials compare across performance, fabrication, and cost — helping engineers, fabricators, and designers select the right option for their projects.
Impact Strength and Durability
Polycarbonate is the standout choice when toughness matters. It is 20–30 times stronger than acrylic and virtually unbreakable, making it indispensable in high-risk environments such as security glazing, riot shields, machine guards, and sports arena barriers. Acrylic, while not as impact-resistant, is still 10–17 times stronger than glass, making it suitable for applications like aquariums, skylight domes, and retail fixtures where maximum durability is not required.
Optical Clarity and Scratch Resistance
Acrylic excels in clarity, transmitting up to 92% of visible light for a bright, glass-like appearance. It naturally resists yellowing outdoors and is often the preferred material for outdoor signage and display projects. Acrylic also has a harder surface, offering superior scratch resistance and the ability to be polished back to like-new clarity. Polycarbonate provides slightly less clarity (86–88% light transmission) but balances transparency with unmatched toughness. Hard-coat finishes are typically used to improve its abrasion resistance.
Cost and Fabrication
Acrylic is generally 30–35% less expensive than polycarbonate, making it the cost-effective choice when impact resistance is not the primary concern. It is also easier to fabricate, offering clean results when laser cut, flame polished, or solvent bonded — ideal for decorative and display applications. Polycarbonate, by contrast, requires machining with saws, routers, or CNC tools, as laser cutting causes melting. While more expensive, polycarbonate often delivers long-term savings in demanding environments where replacements would otherwise be frequent.
Application Highlights
- Polycarbonate: Security glazing, skylights, greenhouses, machine guards, automotive headlight lenses, protective eyewear.
- Acrylic (Plexiglass): Retail displays, aquariums, signage, architectural panels, sneeze guards, medical and food service enclosures.
Bottom Line
Choosing between polycarbonate and acrylic depends on priorities: strength and safety favor polycarbonate, while clarity, scratch resistance, and cost efficiency favor acrylic. Both materials continue to play vital roles in industrial, commercial, and consumer markets, offering durable and versatile glass alternatives.
Source: Interstate Plastics – Polycarbonate vs Acrylic
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