Two of the Most Popular Clear Plastics — And How to Choose
When engineers, designers, and fabricators need a clear, strong, lightweight material, the conversation usually comes down to two options: acrylic and polycarbonate. Both are excellent materials, but they perform very differently depending on the application. Choosing the wrong one can cost you time, money, and performance.
At American Acrylics, we’ve been laser cutting and fabricating both materials since 1973. This guide will help you understand the key differences so you can make the right call for your project.
What Is Acrylic?
Acrylic (also sold under brand names like Plexiglas® and Lucite®) is a thermoplastic known for its optical clarity, surface hardness, and ease of fabrication. It machines cleanly, polishes to a glass-like finish, and is available in an enormous range of colors, textures, and thicknesses.
Acrylic is the go-to material for signage, display cases, mirror panels, protective shields, and architectural applications.
What Is Polycarbonate?
Polycarbonate (Lexan® is the most recognized brand name) is a tougher thermoplastic that trades some optical clarity for dramatically higher impact resistance. It’s the material used in bullet-resistant glass, safety eyewear, and machine guards.
Acrylic vs. Polycarbonate: Head-to-Head Comparison
| Property | Acrylic | Polycarbonate |
|---|---|---|
| Impact Resistance | Good | Excellent (30x stronger) |
| Optical Clarity | Excellent (92% light transmission) | Good (88% light transmission) |
| Surface Hardness | Harder, more scratch-resistant | Softer, scratches more easily |
| Machinability | Excellent — cuts cleanly | Good — can melt or chip |
| UV Resistance | Excellent (naturally UV stable) | Fair (requires UV coating) |
| Weight | Lighter | Slightly heavier |
| Cost | Lower | Higher |
| Chemical Resistance | Moderate | Moderate |
When to Choose Acrylic
Acrylic is the better choice when:
- Optical clarity is critical — acrylic transmits 92% of light vs. polycarbonate’s 88%, and it doesn’t yellow over time outdoors.
- You need a polished, glass-like finish — acrylic flame-polishes beautifully and holds a sharp machined edge.
- Cost is a factor — acrylic is typically 35–50% less expensive than comparable polycarbonate sheet.
- UV exposure is expected — acrylic is naturally UV-stable without coatings.
- Tight laser-cut tolerances are required — acrylic cuts cleanly and precisely, ideal for intricate parts and shapes.
Common acrylic applications: retail displays, signage, mirror cut-outs, picture framing, protective barriers, aquariums, and decorative panels.
When to Choose Polycarbonate
Polycarbonate wins when:
- Impact resistance is non-negotiable — polycarbonate is virtually unbreakable under normal conditions, making it ideal for safety glazing and machine guards.
- The application involves high stress or flexing — polycarbonate bends without shattering, where acrylic may crack.
- Temperature extremes are involved — polycarbonate handles a wider temperature range.
- Ballistic or safety certification is required — most bullet-resistant glazing standards specify polycarbonate.
Common polycarbonate applications: machine guards, safety shields, skylights, riot shields, and industrial equipment panels.
The One Thing Most People Get Wrong
Many buyers default to polycarbonate assuming it’s always the “better” material. But for the majority of display, signage, and decorative fabrication work, acrylic is actually the superior choice — it’s clearer, harder on the surface, more UV-stable, and easier to laser cut to tight tolerances.
Polycarbonate’s softness means it scratches easily and requires more careful handling. Its higher cost is only justified when the application truly demands impact resistance.
Why Laser Cutting Makes a Difference
Both materials can be laser cut, but acrylic produces a cleaner edge finish right off the machine — often requiring no secondary polishing for most applications. Polycarbonate can melt slightly at the cut edge, requiring more care with laser settings and sometimes additional finishing steps.
At American Acrylics, our laser cutting equipment is optimized for both acrylic and polycarbonate. We hold tolerances as tight as ±0.005″ on standard parts, with no minimums — so you can order exactly what you need, whether it’s one piece or ten thousand.
Get a Quote for Your Acrylic Parts
Not sure which material is right for your project? Our team has over 50 years of experience helping engineers, designers, and buyers choose the right material and get parts made right. Contact us or request a quote and we’ll help you figure it out.