Polycarbonate vs Acrylic

Acrylic is generally the better choice when clarity, appearance, scratch resistance and cost are the priorities, while polycarbonate is better suited to applications requiring high impact resistance, durability and heat resistance. Both are lightweight alternatives to glass, but the right material depends on how and where the sheet will be used.

Acrylic or polycarbonate as an alternative to glass

Acrylic is one of the most well-known and widely used plastic sheet materials. This type of plastic consists of a combination of acetone, methanol, hydrogen cyanide and sulfuric acid. These are all toxic substances, but the end product is harmless once the production process is complete. Acrylic is thirty times more resistant to impact than standard glass, but only half as heavy – and it’s a lot cheaper! That’s why acrylic glass is often used to replace glass. 

Polycarbonate is a robust, transparent plastic sheet, also known as Lexan. The material is highly resistant to impact, being an astonishing 250 times stronger than glass. This type of plastic sheet is also twice as light as standard glass. Polycarbonate is also one of the few kinds of plastic that can withstand high temperatures. Although this material’s very strong, polycarbonate is easy to process. 

Cast and extruded acrylic: what’s the difference?

There are two types of acrylic sheet: cast and extruded. Cast acrylic is cast into a flat sheet during the production process. Extruded acrylic sheet is rolled after casting, creating a larger surface area. Because an extruded sheet is thinner, it’s more likely to break or tear. So while extruded acrylic is cheaper than cast acrylic, it’s not suitable for projects that require it to be processed.

Types of Lexan: solid and hollow-core sheets

Two types of polycarbonate sheets are available: solid sheets and hollow-core sheets. Hollow-core sheets contain small air-filled spaces, so they’re very lightweight. Solid sheets don’t have these spaces. So they’re a lot heavier but also more robust. In our webshop, you’ll only find solid polycarbonate sheets.

Key differences between polycarbonate and acrylic

Although acrylic and polycarbonate sheets can look very similar, they behave quite differently. The main differences are in their strength, clarity, scratch resistance, flexibility and resistance to heat and weather.

• Strength and impact resistance: Polycarbonate is much more impact resistant than acrylic and is less likely to crack or break when hit. Acrylic is still considerably stronger than glass, but it is more rigid and brittle than polycarbonate.
• Clarity: Both materials are very clear, but acrylic lets slightly more light through than polycarbonate and has a brighter, more glass-like appearance.
• Scratch resistance: Acrylic has a harder surface and is more resistant to everyday scratches. Polycarbonate is softer and can scratch more easily unless it has a protective coating.
• Flexibility: Polycarbonate is more flexible than acrylic and can bend further without breaking. Acrylic is more rigid, although it can be shaped using heat.
• Heat resistance: Polycarbonate can withstand higher temperatures than acrylic, making it better suited to applications where the material may be exposed to more heat.
• UV and outdoor use: Acrylic naturally performs well when exposed to sunlight and is resistant to yellowing. Polycarbonate used outdoors should have suitable UV protection to help prevent discolouration and deterioration over time.

These differences mean that acrylic is often the better choice when clarity, appearance and scratch resistance are most important, while polycarbonate is usually preferred when strength, impact resistance and durability are the priority.

Ordering acrylic or polycarbonate online

Do you require acrylic or polycarbonate for a greenhouse, shed window or another project? You’ll find a wide range of acrylic, polycarbonate, and other plastic sheets in an array of colours and thicknesses in our webshop. We cut the sheets for you in any shape you like. And we can also cut your own design: just upload a DXF file. If you have any other questions, please don’t hesitate to contact us.