When you need parts that are optically clear, virtually unbreakable, and heat-resistant to 130°C — Lexan polycarbonate is the answer. We thermoform Lexan into machine guards, lighting covers, medical housings, and safety shields that outperform glass and acrylic in every demanding application.
250x
Stronger Than Glass
130°C
Max Service Temp
90%
Light Transmission
5+
Lexan Grades Available
Why Choose Lexan
Lexan (polycarbonate) is the premium choice when your application demands optical clarity, extreme impact resistance, or high-temperature performance.
Lexan transmits 88-90% of visible light — nearly as clear as glass. For applications where visibility is critical — machine guards, instrument covers, lighting — nothing else comes close in thermoforming.
250 times stronger than glass, 30 times stronger than acrylic. Lexan is virtually unbreakable — it's the same material used in bulletproof glazing and riot shields. Your parts won't crack, shatter, or splinter.
Continuous use temperature up to 130°C — significantly higher than ABS (80°C) or acrylic (70°C). Ideal for parts near heat sources, lighting applications, and high-temperature industrial environments.
Polycarbonate is inherently flame-retardant — it self-extinguishes when the flame source is removed. FR grades achieve UL 94 V-0 without additives that compromise clarity or mechanical properties.
Lexan maintains tight tolerances across temperature ranges. Low moisture absorption and minimal thermal expansion make it predictable and reliable in precision applications.
Despite being a high-performance engineering plastic, Lexan thermoforms beautifully. Deep draws, compound curves, and complex 3D geometries are all achievable with proper tooling and process control.
Lexan Grade Selection
From optically clear general purpose to flame-retardant and UV-stabilized — we stock and form the right Lexan grade for your specific requirements.
| Grade | Key Properties | Applications | Max Temp | Thickness |
|---|---|---|---|---|
| Lexan GP (General Purpose) | Optically clear, 250x impact strength of glass, excellent dimensional stability | Machine guards, inspection windows, display covers, safety shields | Up to 130°C | 1.5–8mm |
| Lexan FR (Flame Retardant) | UL 94 V-0 rated, self-extinguishing, maintains optical clarity | Electrical panel covers, lighting diffusers, mass transit glazing | Up to 130°C | 2–6mm |
| Lexan UV-Stabilized | Co-extruded UV protection layer, prevents yellowing and hazing outdoors | Outdoor signage, skylights, solar equipment covers, architectural glazing | Up to 130°C | 2–8mm |
| Lexan Textured / Diffused | Matte or prismatic surface, even light distribution, anti-glare | LED lighting covers, display panels, privacy screens, decorative panels | Up to 130°C | 2–6mm |
| Lexan Tinted | Smoke, bronze, or custom tint colors, maintains impact resistance | Automotive lighting, instrument covers, aesthetic enclosures, sun visors | Up to 130°C | 2–6mm |
Lexan Applications
From safety-critical machine guards to precision medical equipment housings — Lexan is the material of choice when clarity, strength, and heat resistance are non-negotiable.
Thermoformed Lexan guards provide 250x the impact strength of glass. Operators can see through them while staying protected from flying debris, sparks, and moving parts.
Thermoformed Lexan diffusers for LED panels, street lights, and industrial lighting. Even light distribution with high transmission. Available in clear, frosted, and prismatic textures.
Lexan's biocompatibility, chemical resistance, and ability to withstand autoclave sterilization make it ideal for medical device enclosures and diagnostic equipment covers.
Transparent or tinted Lexan covers for control panels, instrument clusters, and electrical enclosures. FR grades available for safety-critical applications.
Headlight lenses, tail light covers, instrument panel windows, and interior trim. Lexan's optical clarity and impact resistance make it the material of choice for vehicle glazing applications.
Skylights, canopy panels, bus shelter glazing, and architectural features. UV-stabilized Lexan maintains clarity for 10+ years outdoors without yellowing.
Optically clear Lexan windows for drone cameras, LiDAR sensors, and thermal imaging equipment. 250x stronger than glass, ensuring optics survive hard landings and debris impacts.
Material Comparison
Both are transparent thermoplastics, but they serve very different applications. Here's an honest engineering comparison.
| Property | Lexan (PC) | Acrylic (PMMA) | Advantage |
|---|---|---|---|
| Impact Strength | 250x glass (virtually unbreakable) | 10x glass (can shatter) | Lexan |
| Heat Resistance | Up to 130°C continuous | Up to 70°C continuous | Lexan |
| Optical Clarity | 88-90% light transmission | 92% light transmission | Acrylic (slightly) |
| Scratch Resistance | Moderate (can be hard-coated) | Good (inherent hardness) | Acrylic |
| UV Resistance | Excellent with UV coating | Excellent (inherent) | Both |
| Chemical Resistance | Moderate (sensitive to solvents) | Good (broad resistance) | Acrylic |
| Flame Retardancy | Inherent (self-extinguishing) | Flammable | Lexan |
| Cost | Higher (2-3x acrylic) | Lower | Acrylic |
The rule of thumb: if the part could get hit, choose Lexan. If optical clarity and scratch resistance matter more than impact, consider acrylic. Ask Nirmal for a recommendation specific to your application.
Thermoforming Expertise
Polycarbonate is more demanding to thermoform than ABS or HIPS. It requires precise temperature control (higher forming temperatures), careful mold design (to avoid stress whitening), and controlled cooling. Formpack's 35+ years of experience with engineering thermoplastics means we know how to handle Lexan properly.
PC requires forming temperatures of 180-220°C with narrow processing windows. Our infrared heating systems provide zone-by-zone control for uniform sheet temperature.
Improper forming causes stress whitening and reduced impact strength. Our tooling and process parameters are optimized to minimize residual stress in PC parts.
Lexan's toughness makes it difficult to trim with conventional methods. Our 5-axis CNC routers deliver clean, precise edges without cracking or delamination.
Every Lexan part is inspected for optical clarity, stress marks, and dimensional accuracy. We use polarized light inspection to detect internal stress patterns.
Related Resources
Send us your drawings or 3D models. We'll recommend the right Lexan grade, review your design for thermoformability, and quote your project — typically within 48 hours.