PT 042 Fabrication Guide

User Manual: PT-042

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Fabrication Guide
Makrolon® polycarbonate sheet

Contents
Fabricating

Finishing

Sawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Shearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Sanding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Jointing-Planing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Solvent Polishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Laser Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Die Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Hot Stamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Screen Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Paint and Ink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Forming
Glazing Information

Brake Bending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Cold Bending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Thermoforming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Installation Guidelines and Procedures . . . . . . . . . . . . . . . . 18
Cleaning and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Predrying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Forming Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Heating Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Shading or Screening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Molds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Mold Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Free Blown Billow Forming of Dome . . . . . . . . . . . . . . . . . .12 .
Free Drawn Vacuum Dome Forming . . . . . . . . . . . . . . . . .12
Registration Forming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Drape Forming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Strip Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Product Selector
Product Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Competitive Offsets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Warranties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Technical Information
Physical Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Environmental Resistance . . . . . . . . . . . . . . . . . . . . . . . 23

Bonding/Fastening
Mechanical Fastening . . . . . . . . . . . . . . . . . . . . . . . . . .14
Solvent Bonding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Transfer Tape Bonding . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Fabricating
CIRCULAR SAWS

CIRCULAR SAW TROUBLESHOOTING

A circular saw blade with carbide teeth utilizing the “triple
chip” tooth design is the preferred method of cutting
Makrolon® Polycarbonate Sheet. Table or overhead
panel saws are normally used.

PROBLEM: Melting or Gummed Edges
SUGGESTED SOLUTIONS:
1. Increase blade tooth size
2. Reduce saw speed
3. Increase feed rate
4. Use air to cool blade
5. Use blade lubricant compatible with
Makrolon Polycarbonate Sheet
6. Inspect blade for sharpness
7. Check blade-fence alignment
8. Reduce number of sheets in stack

Circular saws should be run in the speed range of 60008000 ft/min. Blades for cutting 3/32˝ and thicker material
should have 3-5 teeth per inch. The hook or rake angle
should be 10°-15°. When sawing thin-gauge Makrolon
Polycarbonate Sheet, it is important to have a good
supporting edge on the saw table with minimal gap
between the saw blade and table supporting edge. Be sure
tabletops are smooth and free from projections that might
scratch or mar Makrolon Polycarbonate Sheet.

PROBLEM: Chipping
SUGGESTED SOLUTIONS:
1. Decrease blade tooth size
2. Increase saw size
3. Provide better clamping and/or support for sheet stack
4. Reduce feed rate
5. Check blade and arbor for wobble
6. Inspect blade for sharpness

Hold Down
Blade

Makrolon®

Fence

Gap between saw
blade and table–
minimize

Router Bit Suppliers:
Dino Saw Company
340 Power Ave.
Hudson, NY 12534
Tel: (518) 828-9942
www.dinosaw.com

Onsrud Cutter
800 Liberty Drive
Libertyville, IL 60048
Tel: (800) 234-1560
www.onsrud.com

Boshco Inc.
144-A Rangeway Road
North Billerica, MA 01862
Tel: (978) 667-1911
www.boshco.com

Saw Blade Suppliers:
Forrest Manufacturing
General Saw Corp.
457 River Road
2518 Andalusia Blvd.
Clifton, NJ 07014
Cape Coral, FL 33909
Tel: (800) 733-7111
Tel: (800) 772-3691
www.forrestmanufacturing.comwww.generalsaw.com
Dino Saw Company
FTM, Inc.
340 Power Ave.
6160 Cobblestone Rd.
Hudson, NY 12534
Placerville, CA 95667
Tel: (518) 828-9942
Tel: (530) 626-1986
www.dinosaw.com
www.thefabricatorssource.com

Triple Chip Alternate
Tooth Design

BAND SAWS
It is important to
feed the sheet
against the rotation
of the router bit and
to provide a fence
for sizing when
making straight cuts.

Band saws are useful for trimming formed parts or irregular
shapes. Band saws should be run at 2500-3000 ft/min
and have 8-12 teeth per inch. Coarser (larger tooth)
blades perform better with thicker gauge Makrolon®
Polycarbonate Sheet. Proper support of the part to be
trimmed is important because vibration may induce
cracking if the cut is not smooth. Sanding the edge
smooth after cutting is recommended.

Makrolon®
Table
Polycarbonate Sheet

Fence
Feed Direction
Router Bit Fence

BAND SAW BLADE DESIGN

LASER CUTTING
1˝

Makrolon Polycarbonate Sheet can be cut using industrial
cutting lasers. Edges may become amber or brown when
laser cutting. For information on laser cutting equipment and
part cutting services, contact the manufacturer of your
equipment or the suppliers listed on this page.

8-12 teeth
per inch

SHEARING
Makrolon Polycarbonate Sheet may be sheared using a
conventional sheet metal power shear. It is important to
adjust the top blade clearance in relationship to the bed
blade. A clearance of .001˝ is desirable to avoid a rough
edge cut. Shear single sheets only.

BAND SAW TROUBLESHOOTING
PROBLEM: Melting or Gummed Edges
SUGGESTED SOLUTIONS:
1. Increase tooth size
2. Reduce saw speed
3. Use air to cool blade
4. Check blade sharpness
PROBLEM: Chipping
SUGGESTED SOLUTIONS:
1. Decrease tooth size
2. Slow down stock feed rate
3. Provide better clamping and/or support
to eliminate vibration
4. Check blade sharpness

Knife
Edge

Top Blade

Bed Blade

ROUTING
Routing produces a smooth edge on Makrolon Polycarbonate Sheet and may also be used to cut curved
or irregular shapes. Routers with a speed of 20,000 to
25,000 rpm are preferred. Use straight (fluted 2 or 3)
carbide-tipped or high-speed steel router bits. Bits should
be 1/4˝ to 1/2˝ diameter for best results. Use a router with
at least 1 H.P. motor.

Laser Cutting Equipment Supplier:
Preco Laser Systems
500 Laser Drive
Somerset, WI 54025
Tel: (715) 247-3285
www.precolaser.com

Laser Cut Parts:

Special care must be used when routing–Use proper
guarding and eye protection. Stock feed rates must be
monitored closely. Feeding Makrolon Polycarbonate Sheet
at excessive rates can cause vibration and cracking.

Laser Engineering Inc.
444 North York Road
Elmhurst, IL 60126
Tel: (630) 530-0500
www.laserengineering.com

Preco Laser Systems
500 Laser Drive
Somerset, WI 54025
Tel: (715) 247-3285
www.precolaser.com

Fabricating cont’d.
DIE CUTTING
Die cutting Makrolon® Polycarbonate Sheet in
gauges up to .080˝ thick is normally achieved utilizing the
following steps.

Regulate pressure and speed until a continuous spiraling chip
is observed. Use air or water as a coolant if required. Using
cutting oils may cause crazing. Be extremely careful if using
taps or self-tapping screws; tapping creates notches that
can result in stress cracks because polycarbonate is a notchsensitive material, like most clear plastics. Recommended
drill speed is 350-1750 rpm.

Steel rule dies mounted in a press provide good results.
The shear strength of Makrolon Polycarbonate Sheet is
10,000 psi which is appropriate for die cutting methods.
Calculating the required press tonnage to cut Makrolon
Polycarbonate Sheet:

CROSS SECTION-BLADE GRINDS

F= P x A
2,000
F= Required force in tonnage of the press
P=10,000 psi (shear strength of Makrolon
Polycarbonate Sheet)
A=The sectional area to be cut

30°

.020˝

15°
.030˝

10°-15°

5°
10°
30°
30°

Example: Die cut 12˝ x 20˝ x .030˝ thick rectangle
Total length of cut = 20˝ + 20˝ + 12˝ + 12˝ = 64˝
Shear area = Total length x thickness (.030˝)
or 64˝ x .030˝ =1.92 in2
Required force = P = 10,000 psi

15°

Facet
Bevel

Side
Bevel

90°-188°
included
cutting-lip
angle

Press tonnage (PT.) = 9.6
Use 3 PT. (.042˝) thick steel to fabricate steel rule die. Flush
or center bevel ground rule provides a clean cut. Facet
ground steel rule is used to cut thicker gauge Makrolon
Polycarbonate Sheet (above .060˝).

15°
Clearance angle
0°-5° negative rake

Be sure platens are parallel and that the backup pad is in
good condition. Backup pads can be made from a wide
variety of materials such as nylon, HDPE, etc.

Hole Dia.
1/8˝
1/4˝
1/2˝

Upper Press Platen

Lower Press Platen
Makrolon®
Polycarbonate Sheet

Center
Bevel

.042˝

DRILL BIT DESIGN

F= P x A = 10,000 psi x 1.92 in2 = 9.6
2,000
2,000 lbs.

Steel
Rule

.042˝

.084˝

Plywood
Foam
Rubber

Drill Speed (RPM)
1750
1000-1500
350-500

Die Cutting Equipment Suppliers:
Backup
Pad

National Steel Rule Die Co.
3580 Lightner Boulevard
Vandalia, OH 45377
Tel: (937) 667-8407
www.zedindustries.com

Atlas Die, Inc.
2000 Middlebury Street
Elkhart, IN 46516
Tel: (574) 295-0050
www.atlasdie.com

Reversed
Specialty Drill Bit Suppliers:
Craftics, Inc.
PO Box 91930
Albuquerque, NM 87199
Tel: (505) 338-0005
www.craftics.com

DRILLING
Makrolon Polycarbonate Sheet is easily drilled using ordinary
high-speed steel drill bits.

FTM, Inc.
6160 Cobblestone Road
Placerville, CA 95667
Tel: (530) 626-1986
www.thefabricatorssource.com

Forming
BRAKE BENDING

THERMOFORMING

Makrolon® Polycarbonate Sheet can be brake bent to 90°
angles in gauges ≤ .100˝. Attempts at bending heavier
gauges can result in cracks or breakage at the time of
bending or later due to high levels of stress in the bend
area. For this reason strip heat bending is recommended on
all gauges ≥ .118˝.

Makrolon Polycarbonate Sheet can be thermoformed on
standard equipment. Vacuum forming, free blown forming,
and line bending are the most extensively used processes.

COLD BENDING

PREDRYING Makrolon®
POLYCARBONATE SHEET

While most standard forming techniques can be used,
critical process modifications specific to polycarbonate are
necessary to ensure uniform and repeatable formed parts.

Makrolon® GP and Makrolon® SL Polycarbonate Sheets may
be cold-bent with the minimum radius based upon the sheet
thickness. As a guideline, the material can be radiused to
100 times the thickness: (R=T x100).

Makrolon Polycarbonate Sheet must be dried before
thermoforming because polycarbonate absorbs moisture at a
high rate. Trapped moisture forms vapor above 250°F, and the
vapor expansion creates bubbles in the sheet.

COLD BEND RADII
Sheet Thickness ( T )

Sheets of Makrolon Polycarbonate sheet should be placed
in a dehumidifying air circulating oven for predrying.
Temperature should be 250°F and monitored with controls.
Recommended predrying time periods are shown below.
Be cautious. Polycarbonate sheet begins absorbing
moisture immediately upon removal from the predrying
oven. The rate of absorption is dependent upon the ambient
dew point. For this reason, it is crucial to transfer the sheet
directly to the forming machine as quickly as possible.

Minimum Radius (R)

1/8˝
3/16˝
1/4˝

12.5˝
18.7˝
25.0˝

Note: Makrolon® AR Polycarbonate Sheet is recommended for flat
glazing only.

FORMING EQUIPMENT
The thermoforming machine should be capable of generating
and maintaining a vacuum of 20 in. Hg pressure throughout
the thermoforming cycle.
Vacuum forming machines with infrared heating elements
perform well for Makrolon Polycarbonate Sheet forming.
Rotary and shuttle designs with automatic or semi-automatic
controls are most suitable. Key features of this type for
equipment are timer control accuracy, uniform heating
sources, and sufficient vacuum power. Single-sided heating
has proven effective for Makrolon Polycarbonate Sheet in
gauges up to .177˝. For thicknesses above .177˝, it is
recommended that dual-sided heating ovens be used for
effective radiation penetration.

HEATERS

DRYING TIME (HOURS)
THICKNESS
.093˝
.118˝
.150˝
.177˝
.236

250°F
4
6
8
12
24

Infrared cal rod, coiled nichrome or ceramic heating elements
provide the best heating sources. Gas-fired heaters or
convection ovens are not normally used with polycarbonate.
Uniform heating of the sheet is critical. Radiation absorption
graphs for polycarbonate are available. These graphs help
match the emissivity of the heating element with the sheet
for the most efficient heat penetration.

180°F
8
14
20
30
50

Note: Makrolon® AR Polycarbonate Sheet is recommended for flat
glazing only.

Forming cont’d.
HEATING CYCLE

SHADING OR SCREENING

Heating Makrolon® Polycarbonate Sheet for vacuum forming
requires heat penetration to achieve a 350°F to 360°F. The
heat required will be higher for more complex shapes. When
Makrolon Polycarbonate Sheet reaches forming
temperature, uniform “sag” occurs. The amount
of sag depends on the size and thickness of the sheet.
A 12˝ x 12˝ x .060˝ sheet will sag approximately 1˝.
A 36˝ x 36˝ x .177˝ sheet may sag 4˝- 6˝ at the center.
Once uniform temperature has been achieved, timers can
accurately reproduce the condition, and part-to-part
consistency can be maintained.

Shading is often used to balance out hot spots in an oven
for uniform temperature. Shading may also be used to
control the sag of Makrolon Polycarbonate Sheet
during heating.

PROCEDURE:
O Use heavy-duty metal screening to shade the major
portion of the clamped sheet, leaving several inches
along the edges unshaded to compensate for
cooler areas.
O Screens can be installed permanently or placed loosely
above the sheet, depending on how much shading
is required.

PROCEDURE:
O Sheet thicknesses up to .177˝ gauge can be heated
from one side. Above .177˝ gauge, two-sided heating is
normally required to significantly enhance productivity.

HELPFUL HINTS:
O Use slow heating. This is particularly important with
heavier gauges in order to prevent gradient heating.

O Heat source is removed and heated sheet is forced over
or into mold where vacuum is applied.

O Allow heat to reach uniformity at the center of
the sheet.

HELPFUL HINT:

O The heating rate may be reduced by lowering the
heat intensity or by moving the sheet farther away
from the heaters.

O Makrolon Polycarbonate Sheet “sets up” very quickly
compared to other thermoplastics and can be removed
from the mold in a short period of time.
Caution:
Makrolon Polycarbonate Sheet remains quite hot
during this cycle and care must be observed when
handling finished parts.
O Throughout the vacuum forming process, it is
imperative that dust and dirt be controlled. Makrolon
Polycarbonate Sheet has a static charge that attracts
foreign particles which can create surface imperfections.
Molds also attract dust particles and should be cleaned
to avoid creating surface defects.

Thermoforming troubleshooting
PROBLEM

POSSIBLE CAUSE

SUGGESTED SOLUTION

Bubbles or blisters

Too much moisture in sheet

Pinholes or surface marks
Mark off

Vacuum holes too large
Mold surface too smooth
Mold surface too rough

- Predry sheet for longer time period
- Check predry oven temperature
- Use smaller diameter vacuum holes
- Vapor hone or use extra fine emery
cloth to lightly abrade mold surface
- Preheat mold

Sheet too cold to form

- Heat sheet for longer time period

Uneven heating

- Check heaters
- Screen “hot” areas
- Heat sheet for longer time period
- Check vacuum system for leakage
- Increase vacuum
- Reduce heating cycle
- Redesign mold
- Use mechanical assist/bridging

Sheet pulls out of damping
frame during forming
Non-uniform sag
Incomplete part formation detail

Sheet too cold
Inadequate vacuum

Webbing

Sheet too hot
Improper mold spacing

Thermoforming Machines:
Brown Machine
Division John Brown Plastics
330 North Ross Street
Beaverton, MI 48612
Tel: (517) 435-7741
www.brownmachine.com
Plastic Thermoforming Systems
The Shuman Company
3232 South Boulevard
Charlotte, NC 28209
Tel: (704) 525-9980
www.shuman.biz

Drying Ovens:
Grieve Corporation
500 Hart Road
Round Lake, IL 60073
Tel: (847) 546-8225
www.grievecorp.com

Plasti-Vac, Inc.
214 Dalton Avenue
P.O. Box 5543
Charlotte, NC 28206
Tel: (800) 438-4139
www.pvi-plastivac.com

Forming cont’d.
MOLDS

TYPICAL MOLD MATERIALS
THERMAL CONDUCTIVITY PROPERTIES

In general, male molds are more suitable for vacuum
forming. However, other factors such as part size, finish,
and shape dictate mold design. Choice of mold materials
should be determined by considering the length of the
production run. For optimum cost-effectiveness, use the
least expensive material that will take the entire run.

Material

Heat Transfer
Rate Factor

K Value
btu/hr/sf/f/ft

6190
1238
24-47
8.29
6.24
4.48

130
26
.52-.87
.17
.13
.09

Aluminum
Steel
Aluminum filled epoxy
Plaster of Paris
Epoxy
Wood (maple)

It is evident that thermal transfer is much more efficient with
aluminum than wood. Wood, however, can be utilized for
short-run projects.
Makrolon® Polycarbonate Sheet reproduces mold surface
finish accurately, even to the point of replicating wood grain
in a smooth wood mold.
Sometimes it is desirable to reduce the polish on a steel or
aluminum mold by utilizing a vapor hone or bead blast. This
is due to the fact that if the mold surface is too smooth, air
entrapment can occur creating “mark off.” For best results,
use fine hand sanding on the surfaces. Sanding provides
tiny channels for air evacuation to prevent air entrapment.
This may have to be repeated on long production runs, as
the sanded finish smoothes out from extended use.

MOLD DESIGN
Draft Angles: Minimum 5°-7° or greater for ease of part
removal from the mold.
Radii and Fillets: Use generous radii wherever possible for
more uniform walls and greater rigidity. On female tooling,
use permanent corner fillets.
Vacuum Holes: In order to form the sheet as rapidly as
possible, use sufficient holes for fast evacuation of air from
between the sheet and the mold. In female molds, use air
evacuation holes at all deep draw areas, especially around
the mold perimeter where the sheet will be drawn last.

When constructing the mold, mold shrinkage should be a
design consideration. Shrinkage for Makrolon Polycarbonate
Sheet is .005˝-.007˝. The heating/cooling cycle and the type
of vacuum forming equipment will also influence results.

HELPFUL HINTS:
MOLD SHRINKAGE

O Keep the diameter of the holes small (approximately
1/64˝-1/32˝ diameter) to avoid marking on the sheet.
Long, thin slots may be designed for air evacuation in
female tooling.

3.021˝

O Use vapor honed or fine sanded finishes.

Mold

O Avoid sharp corners to minimize stress.
O Avoid highly polished surfaces that can cause mark off.
O Always preheat mold. Cold molds can create surface
defects and/or warped parts.
O If mold temperature becomes too high during thermoforming runs, Makrolon Polycarbonate Sheet
could stick to the mold. It is recommended that the
mold temperature not exceed 260°F.

3.00˝ Part

FORMING GUIDELINES

MOLD MATERIALS AND MOLD DESIGN
Makrolon Polycarbonate Sheet allows the use of a variety of
mold materials: wood, filled and unfilled polyesters, epoxies,
and metals.

Sheet Temperature:
Typical: 340˚F-380˚F

Molds for vacuum forming need to take only 14 psi, so there
is little wear on the tooling with low pressure of the material
against the mold surface.
10

Optimum:

350˚F-360˚F

Mold Temperature:

210˚F-260˚F

SHEET
SHEET

CLAMP
HEATER

CLAMP

FEMALE
MOLD

MALE
MOLD

WORK
TABLE

VACUUM

Straight vacuum forming in a female mold is
recommended for low-profile parts where deep
draw is not a requirement.

PLUG

SHEET

HEATER

Drape forming over a male mold usually results in
better material distribution and depth-to-diameter
draw ratios.

FORCE
HEATED SHEET

SHEET

HEATED SHEET

CLAMP
MOLD

MALE
MOLD

VACUUM

CLAMP

WORK
TABLE

VACUUM
BOX

SHEET

VACUUM
VACUUM

Thinning of material in deep-mold cavities can
be overcome by use of plug assists designed for
fast penetration.

Vacuum forming with snap-back can reduce
starting sheet size, aid material distribution, and
minimize chill marks.

SHEET
HEATED SHEET

CLAMP
MALE
MOLD

MOLD

FORCE
PLUG
HEATED
SHEET

CLAMP
AIR
ENTERING

SHEET

FEMALE
MOLD
VACUUM APPLIED

Air-slip forming is similar to vacuum snap-back
except that heated sheet is billowed up and
mold rises to meet it.

AIR BLOWS SHEET UP

VACUUM DRAWS
SHEET AGAINST MOLD

Forming with billow plug is often used to produce
thin-wall items with depth-to-diameter draw ratios
up to 1.5:1.
11

Forming cont’d.
FREE BLOWN BILLOW FORMING OF DOME

REGISTRATION FORMING

This process is utilized for forming dome shapes from
Makrolon® Polycarbonate Sheet. The procedures and
equipment are the same as vacuum forming with the
exception of the mold. Billow forming can be done
with positive air pressure (free blown) or negative
pressure (vacuum).

Makrolon Polycarbonate Sheet is suitable for registration
vacuum forming. Because the material is extruded, it is
important to orient the sheet so that each part is screened
and formed in the same direction each time. Material should
be specially ordered for this application. Dimensional stability
tests indicate Makrolon Polycarbonate Sheet in free form
releases stress about 2-4% in the direction of extrusion and
1% across the extrusion web.

PROCEDURE:
O Preheat all clamps and tooling (240°F-260°F).

BLOWN DOME FORMING

O Predry Makrolon Polycarbonate Sheet in air
circulating oven at 250°F. (See page 7 for
recommended drying times.)

Heat Source

O Place Makrolon Polycarbonate Sheet in
clamping frame of thermoforming machine.

Clamp
Frame

O Heat sheet until uniform sag occurs (340°F-380°F).

Air
Box

O Remove heat source.

Air Inlet
Makrolon®
Polycarbonate
Sheet

O Lower pressure box to seal air supply pressure.
O Apply air pressure. Initial air pressure is high, and as
dome is created, air pressure is reduced.
O When overall height is achieved, maintain positive
air pressure until part cools.
O Be sure air source is properly filtered and uniformly
dispersed for even formation of dome.

Sag
Microswitch

O Utilize electric eye designs or microswitches to
assure consistent product.

Electric
Eye

O When dome reaches electric eye, set height. The
eye controls air pressure through a solenoid valve to
control cooling.

DRAWN DOME FORMING
Air Pressure

O Remove and trim.

Heater

FREE DRAWN VACUUM DOME FORMING
Clamp
Frame

Follow steps involved in vacuum thermoforming,
including predrying.

Vacuum
Box

PROCEDURE:
O Place sheet in clamping frame of thermoforming
machine.

Vacuum Line

O Heat sheet until uniform sag occurs (340°F-380°F).
O Remove heat source.
O Apply vacuum seal box and apply vacuum pressure.
O Use electric eye or microswitch to assure consistency of
depth of dome.

Sag

O Retain small amount of vacuum pressure until dome
sets up.

Electric
Eye

O Remove and trim.
Apply Vacuum

DRAPE FORMING
O Avoid bending short tabs on wide parts; warping
may occur.
O For thicker gauge sheet, use two-sided heating. (Repeated
turning with one-side heating may also achieve sufficient
heat penetration.)

Pressure Frame

Makrolon®
Polycarbonate
Sheet

Mold

O Thicker gauge sheet (above 1/8˝) can be grooved with
a 1/16˝ radius to allow sharper bends.

Pressure Frame

HEAT BENDING DEVICE
Mold

Makrolon
Polycarbonate
Sheet

3/4˝
Transite
approx.
6˝ wide

Nichrome
resistance
wire (or
Calrod
type
heater)

Felt Covering for Mold

DRAPE FORMING

Milled groove to accept Nichrome
wire (approximately 1/16˝-1/8˝
below surface of Makrolon®
Polycarbonate Sheet). Do not allow
wire to contact sheet directly.

Simple contours can be achieved by drape forming
Makrolon® Polycarbonate Sheet. This method can be
utilized to manufacture a part requiring a simple radius of
curvature. Mold material can be wood, fiberglass or
aluminum covered with felt.

Rheostat
for temp.
control

STRIP HEATING TROUBLESHOOTING

PROCEDURE:

PROBLEM: Bubbles in bent area
POSSIBLE CAUSE: Too much heat
SUGGESTED SOLUTION: Reduce temperature

O Predrying Makrolon Polycarbonate Sheet may
not be necessary.
O Bring to forming temperature of about 300°F-320°F in
the oven.

PROBLEM: Warpage
POSSIBLE CAUSE: Part too wide for heat bending
SUGGESTED SOLUTION: Heat from both sides to provide
more uniform heat penetration

O Remove parts and immediately place over a male mold
covered with felt.

PROBLEM: Heating not uniform
SUGGESTED SOLUTION: Check for air drafts which may
affect uniform cooling

O Apply pressure until cool.

STRIP HEATING Makrolon®
POLYCARBONATE SHEET

PROBLEM: Cooling not uniform
SUGGESTED SOLUTION: Do not try to bend short
(under 1˝) sections

Strip heating or line bending is commonly used for producing
localized angular bends in polycarbonate. Generally, predrying
is not required for material thicknesses of .118˝ or less.

PROBLEM: Mark off
POSSIBLE CAUSE: Heater is contacting plastic. Transite is too
hot. Masking is not removed over sufficient
area where heat is being applied
SUGGESTED SOLUTION: Lower heat source

PROCEDURE:
O Remove protective masking in bend area.
O Regulate nichrome heat source to 340°F-365°F maximum.
O Place sheet over heat source at bend area.

Strip Heaters:

O Allow heat to soften material–time depends on gauge.

FTM Inc.
6160 Cobblestone Road
Placerville, CA 95667
Tel: (530) 626-1986
www.thefabricatorssource.com

O Remove sheet and make desired bend on wood or heavy
fabric-covered aluminum fixture.
O Bend immediately–polycarbonate sets up quickly.

Craftics, Inc.
PO Box 91930
Albuquerque, NM 87199
Tel: (505) 338-0005
www.craftics.com

O Allow sheet to cool in fixture.
O Some bends may require a degree of overbending to
achieve desired angle after sheet sets up. Strip heating
works best for relatively short parts–wide parts may warp.
13

C.R. Clark & Co.
1272 Aquila Loop
Celebration, FL 34747
Tel: (800) 676-7133
www.crclark.com

Bonding and fastening
MECHANICAL FASTENING

NEEDLE APPLICATOR

Aluminum rivets and machine screws may be used to join
Makrolon® Polycarbonate Sheet to other materials by
utilizing proper attachment methods.
Drill oversized holes and use washers to distribute and
cushion localized stress. Be sure to consider differentials in
expansion factors for dissimilar materials. Be sure drilled
holes are smooth and free from cracks.
Oversized
Hole

Resilient
Washer
Makrolon®
polycarbonate
sheet

HELPFUL HINTS:

Resilient
Washer

O Edges must be clean and free from dirt.

SOLVENT BONDING

O Surfaces should be smooth and properly aligned.

Many applications for Makrolon Polycarbonate Sheet
involve fabrication of sheets to construct three-dimensional
shapes.The most popular method is to solvent bond.
Makrolon Polycarbonate Sheet solvent bonding can be
achieved using methods employed in fabricating other
thermoplastics such as acrylic. The two most common
methods are needle type applicator capillary action and
edge dipping. Both methods rely on smooth edge
preparation, pressure, and curing.

O Apply even pressure to reduce bubbles in the bond area.

TECHNIQUES TO REDUCE WHITENING:
1. Fabricate in a climate-controlled area with low
relative humidity.
2. The addition of 10% glacial acetic acid in the solvent
reduces whitening.
3. Thickening the solvent with polycarbonate resin or
sawdust promotes slower curing and reduces whitening.

It should be noted that solvent bonding will significantly
reduce the strength of polycarbonate.

4. Joint cure time is somewhat longer than acrylic. Be sure
to retain fixture pressure until the joint is solid.

PROCEDURE:

Note: Use extreme caution when working with solvents. Adequate ventilation is essential.
Control exposure levels according to OSHA guidelines. Obtain Material Safety Data
Sheets from the solvent manufacturer.

O Smaller items with flat surfaces can be bonded by
placing the pieces together and applying the solvent
along the edges using a needle applicator or hypodermic
syringe. Make sure the solvent flows along the entire joint.
O For bonding larger items, immerse the surfaces to be
joined in the solvent until the material is softened.
O Clamp them in position and hold until the bond is set.

Adhesive Suppliers:
Industrial Polychemical
Weld-On Adhesives
17109 South Main Street
Gardena, CA 90247
Tel: (800) 421-2677
www.ipscorp.com

Pacer Tech Industrial
9420 Santa Anita Ave.
Rancho Cucamonga, CA 91730
Tel: (800) 538-3091
www.supergluecorporation.com

Hartel Enterprises
12970 Branford St., Suite F
Pacoima, CA 91331
Tel: (818) 767-0861

Dow-Corning Corporation
3901 South Saginaw
Midland, MI 48640
Tel: (989) 496-4000
www.dowcorning.com

General Electric Company
260 Hudson River Road
Waterford, NY 12188
Tel: (518) 237-3330
www.gesilicones.com

Ciba Specialty Chemicals Performance Polymers
4917 Dawn Avenue
East Lansing, MI 48823
Tel: (800) 367-8793
www.loctite.com

Lord Corp.
2000 West Grandview Blvd.
Erie, PA 16514
Tel: (814) 868-3611
www.lord.com

Makrolon® POLYCARBONATE SHEET ADHESIVE GUIDE
ADHESIVE
Methylene
Chloride

JOINS MAKROLON
SHEET TO
Makrolon
Polycarbonate Sheet
Acrylic

Weld-On Series

Makrolon
Polycarbonate Sheet

Urethane

Virtually Anything

COMMENTS

COLOR

1-OR 2-PART APPLICATION
SYSTEM
METHOD

SETUP
TIME

CURE
TIME

SUPPLIER

- Clear Solvent
- High tensile
strength products
- Low-impact
resistance

Clear

One

Flow

20 sec.

48 hrs
@ 75°F

Chemical
Supply House

- Various viscosities
offering quick
bonds

Clear

One

Flow

1 min.

24 hrs.

IPS/Weld-On

Butyrate

RTV Silicone

Metal/Plastic/Wood

- Clear, flexible
high-impact bond
- Excellent peel
strength
- Excellent shear
strength
- Excellent heat
resistance
- Good thermal
expansion

Clear

Two

Flow

8 hrs.
@ 75°F

Various
Colors

One

Tubes, Caulkers

60 min.
@ 75°F

Hartel
5 hrs.
Enterprises, Inc.
@ 150°F
or 7 days
Formulated
@ 75°F Systems Group
24 hrs.

Dow-Corning
GE Silicones

TRANSFER TAPE BONDING

WELDING

Achieving a strong edge bond using solvents on
thin-gauge thermoplastics is extremely difficult due to
the reduced size of the bond area. Structural bonding of
thin-gauge Makrolon® Polycarbonate Sheet can be
accomplished, however, by utilizing acrylic-based transfer
tapes along with slight design modifications.

While mechanical fastening and solvent bonding are the
most often recommended methods for joining plastics,
another alternative is welding. Ultrasonic, radio frequency,
and spin welding have proven to be appropriate. Contact
manufacturers of ultrasonic welding equipment for recommendations on section and joint design.

PROCEDURE:
O Bend a small return on the appropriate part to be
fastened approximately the width of the transfer tape.
O Clean tape contact areas with 50/50 isopropyl
alcohol-water mixture.

Transfer Tape Suppliers:

O Apply transfer tape to the return.

3M/Industrial Specialties Division
3M Center, Bldg. 220-7E-01
St. Paul, MN 55144-1000
Tel: (800) 227-5085
www.3m.com/us/mfg_industrial/adhesives/

O Remove tape masking and press the part into place.

HELPFUL HINTS:
O Rolling the bonded area with a small wood or rubber
roller improves bond strength.

Ultrasonic Welding Equipment:

O A nonstick slip sheet is useful for proper positioning of
large or hard to handle parts.

Branson Ultrasonics Corp.
41 Eagle Road, Suite 1
Danbury, CT 06813-1961
Tel: (203) 796-0400
www.bransonultrasonics.com

O Peel strength of long, lineal bonded areas can be
increased with the addition of a mechanical fastener at
both ends of the bond.

St. Gobain Performance Plastics
1 Sealant Park
Granville, NY 12832
Tel: (518) 642-2200
www.nortonfoam.com

Finishing
SANDING

HOT STAMPING

Makrolon® Polycarbonate Sheet can be sanded using both
wet and dry techniques. Gumming can result from dry
sanding. Wet sanding produces a smooth finish. In both
instances, the part will require further finishing in order to
restore its high gloss.

Makrolon Polycarbonate Sheet is easily decorated by hot
stamping. Normal operating conditions are: head (die)
temperatures 375°F; dwell time 2-3 seconds at 60 psi.
Contact foil manufacturer for recommended application
guidelines.

Makrolon Polycarbonate Sheet can also be buffed using a
2-wheel system. The first wheel uses a buffing compound to
remove shallow scratches. The second buffing wheel is
used for restoring the gloss.

JOINTING-PLANING
A standard woodworking jointer-planer is an excellent edge
finishing machine for Makrolon Polycarbonate Sheet. Blades
must be carbide or high-speed steel. Avoid removal of too
much stock on each pass. 1/64˝ or less stock removal
normally yields the cleanest edge. Trying to remove too
much material results in a rough edge or cracking of
the sheet.
If smoother edges are required, wet sanding with fine grit
sandpaper is recommended.

SOLVENT POLISHING

SCREEN PRINTING

In order to improve the look of saw-cut edges, begin by
sanding the edges smooth. For smoother, glossy edges,
consider solvent polishing with MEK or methylene
dichloride. To prevent humidity blush after drying, it may be
necessary to add a small amount of a slow-drying
component such as diacetone alcohol or glacial acetic acid.
Since Makrolon Polycarbonate Sheet has such good
chemical resistance properties, keep in mind that solvent
polishing cannot be expected to totally eliminate sand
marks from the sheet edge.

Standard silk screening equipment with screens of varying
mesh 8x-16x regulating the amount of ink coverage on
Makrolon Polycarbonate Sheet provides excellent
sign product.
As with all thermoplastics, Makrolon Polycarbonate Sheet
must be clean and free from surface residuals prior
to screening. Many screeners use a prerinse of 50%
water and 50% isopropyl alcohol to clean the surface of
Makrolon Polycarbonate Sheet. Be sure to use soft
nonabrasive cloths when cleaning to avoid scratching
Makrolon Polycarbonate Sheet. Ionized air also provides a
good method for removing lint and dust.

Note: Use extreme caution when working with solvents. Adequate ventilation is
essential. Control exposure levels according to OSHA guidelines. Obtain Material
Safety Data Sheets from the solvent manufacturer.

After screening, separate sheets on a drying rack until ink
is completely dry. DO NOT pack sheets for shipment until
inks are dry.
UV cure inks can be used with heavy gauge
Makrolon Polycarbonate Sheet, but intense or prolonged
UV may have a damaging effect on thin gauges. It is not
recommended for Makrolon Polycarbonate Sheet under
.060 gauge as some loss of physical properties occurs.

PAINTING
Many paint systems are available for Makrolon® Polycarbonate Sheet. As with screen printing it is important that the
surface of the Makrolon Polycarbonate Sheet be clean and
free from surface residuals prior to painting. Many painters
use a mixture of 50% water and 50% isopropyl alcohol to
clean the surface of the sheet. Be sure to dry thoroughly prior
to painting. Use a soft nonabrasive cloth
or sponge to avoid scratching Makrolon Polycarbonate
Sheet. Conventional spray, spray masked, roller coat and
brush are common application methods.

Hot Stamping Foil Suppliers:
Transfer Print Foils, Inc.
9 Cotters Lane
East Brunswick, NJ 08816
Tel: (908) 238-1800
(800) 235-3645
hmt.com/holography.TPF

Foilmark
40 Melville Park Road
Melville, NY 11747
Tel: (800) 645-9177
www.foilmark.com

Crown Roll Leaf, Inc.
91 Illinois Ave.
Paterson, NJ 07503
Tel: (800) 631-3831
www.crownrollleaf.com

Avoid using paints containing toluene, xylene or solvents
that will craze Makrolon Polycarbonate Sheet. Be
careful when using the paper masking for the design.
Sharp knives can notch Makrolon Polycarbonate Sheet and
allow crazing to occur. Be sure not to allow razor
knives to penetrate the Makrolon Polycarbonate Sheet when
cutting through masking paper.

Screen Print Ink Supplier:
NazDar
1087 N. Northbranch Street
Chicago, IL 60622
Tel: (800) 736-7636
www.nazdar.com

A number of companies market paint systems for Makrolon
Polycarbonate Sheet and provide technical advice on
application.

Paint Suppliers:
Spraylat Corporation
716 South Columbus Avenue
Mt.Vernon, NY 10550
Tel: (914) 699-3030
(800) 336-1936
www.spraylat.com

PAINT AND INK REMOVAL
Use caution when removing overspray or drips. Be sure
that the solvent will not attack and craze polycarbonate.
Isopropyl alcohol, VM&P naptha or similar solvents have
been successfully used. Be sure to rinse with clear
water after solvent application. Do not use scrapers,
blades, knives, etc., as they will scratch Makrolon
Polycarbonate Sheet. Always test a small area and observe
possible attack before subjecting large sheet to solvent.

Mathews Paint Company
8201100 Street
Pleasant Prairie, WI 53158
Tel: (800) 323-6593
www.mathewspaint.com

NOTES ON Makrolon® AR
POLYCARBONATE SHEET
Coated sides of Makrolon AR Polycarbonate
Sheet cannot be painted because of the abrasionresistant coating. However, sheet
that is only coated on one-side
(Makrolon AR-1 Polycarbonate
Sheet) can be reverse screened
on the uncoated side using
standard painting techniques for
polycarbonate. This material is
an excellent choice for durable
graphics applications in high
traffic areas.

Red Spot Paint & Varnish Co., Inc.
1107 E. Louisiana Street
Evansville, IN 47711
Tel: (800) 457-3544
www.redspot.com

Glazing information
RECOMMENDED SEALANTS, GASKETS, AND TAPES

INSTALLATION GUIDELINES
Makrolon Polycarbonate Sheet may be installed using wet
or dry glazing systems. However, Bayer MaterialScience
warns against the use of PVC gasketing. The material may
also be used for double-glazing or over-glazing applications
for added insulation and security. Maintain adequate
separation between the glazing panels to prevent touching
during high humidity and/or high heat conditions.
®

Product
Type

Product
Name

Silicone

Dow 795
Dow 999
Trademate®
Silpruf ®
Construction
1200 ®
Spectrem

Gasket

EPDM (60,70D)

Tape

440

Gasket/Tape

Norrene® Foam
V-2100 Urethane

Butyl Tape

Isocryl 5600

Silicone

INSTALLATION PROCEDURES
1. Clean sash and prime if necessary. For replacement
glazing, make sure all old sealant and projections are
removed. Rabbet should be free of burrs and of the
proper depth to allow for expansion of the Makrolon
Polycarbonate Sheet glazing panel.
2. Carefully measure the sash opening. Determine
the appropriate edge engagement and expansion
allowance from Table (on next page). Cut Makrolon
Polycarbonate Sheet to the exact size required, making
sure cut edges are smooth and free of chips and notches.
3. Glaze Makrolon Polycarbonate Sheet with the proper
compatible sealant. While smaller lites allow for the use of
nonhardening oil-based and acrylic-latex caulks (up to
24˝ x 24˝), the thermal and load movements in larger sheet
sizes require high performance, low modulus elastomers
such as silicones.

Manufacturer
Dow-Corning Corp
Midland, MI
(517) 496-4000
General Electric Co.
Waterford, NY
(800) 255-8886
Tremco
Columbus, OH
(800) 321-7906
Tremco
Columbus, OH
(800) 321-6357
Tremco
Beechwood, OH
(800) 321-7906
Norton Company
Granville, NY
(518) 642-2200
Schnee-Morehead
Irving, TX
(214) 438-9111

Many other glazing materials are commercially available which are compatible with
Makrolon Polycarbonate Sheet. Please contact those manufacturers for their
recommended products.
Trademate is a registered trademark of Dow-Corning Corp.
Silpruf is a registered trademark of General Electric Company
Norrene is a registered trademark of Norton Company

WIND LOAD PERFORMANCE
50

Wind Velocity MPH

Windload (PSF)

120
40
30
1/2"
3/8"

20
1/4"

3/16"

10
1/8"

0
24

Short Dimension (Inches)

100
80
60

EXPANSION ALLOWANCES–EDGE ENGAGEMENTS

COMPARATIVE EXPANSION RATES

Sheet Size
24˝x24˝
24˝x36˝
36˝x48˝
48˝x60˝
Expansion 1/8˝x1/8˝ 1/8˝x3/16˝ 3/16˝x1/4˝ 1/4˝x5/16˝
Allowance
Edge
3/8˝
1/2˝
9/16˝
3/4˝
Engagement
Rabbet
1/2˝
11/16˝
13/16˝
1-1/16˝
Depth

Material

in./in. °F

Glass
Makrolon®
Polycarbonate Sheet
Aluminum
Steel
Acrylic

.0000050
.0000375
.0000129
.0000063
.0000410

CLEANING AND MAINTENANCE
Thoroughly rinse with warm water using a soft cloth or
sponge. Wash with mild soap or detergent and rinse
thoroughly with clean water. To prevent water spots,
thoroughly dry the glazing with a chamois or moist sponge.
Do not use abrasive cleaners. Avoid cleaning in direct
sunlight to prevent streaking.

COMPATIBLE CLEANERS
The following cleaning agents are compatible with Makrolon
Polycarbonate Sheet products when used according to the
manufacturer's recommendations:
O Formula 409®
O Top Job, Joy®

EXPANSION ALLOWANCES
As a general guideline, glazing systems should be
designed to allow 1/16˝ per foot of length and width as
the expansion in the sash.

O Palmolive Liquid®
O Windex D with Ammonia D®
Formula 409 is a registered trademark of Clorox Company
Top Job and Joy are registered trademarks of Proctor & Gamble
Palmolive is a registered trademark of Colgate Palmolive
Windex D is a registered trademark of Drackett Products Company

19
18

Product selector
Product Features
Superior Impact Strength

Makrolon®
GP

Makrolon®
SN

Makrolon®
AR

Makrolon®
SL (SunLife)

Makrolon®
FI

Privacy
Patterns

Makrolon®
CG

Hygard®

Enhanced UV Resistance
Forced Entry Protection (UL 972)

N/A

Enhanced Abrasion Resistance
Thermoformable

Cold-Formable

Patterned Sheet

✝

Flame Inhibiting

COMPETITIVE OFF-SETS
Makrolon® Grade
Makrolon® GP
Makrolon® GP Matte
Makrolon® GP Pebble
Makrolon® FD
Makrolon® FI
Makrolon® FI
Makrolon® SL
Makrolon® AR
Makrolon® CG 375
Makrolon® CG 500
Makrolon® CG 750
Hygard® 750
Hygard® 1000
Hygard® 1250
Makrolon® WG
Makrolon® TG

Description
General purpose grade for fabrication
and glazing
Matte texture for privacy glazing
Pebble patterns for privacy glazing
FDA compliant material
Flame inhibiting grade
Flame inhibiting
Thermoformable enhanced UV resistance
Abrasion & UV resistance
Physical attack resistant
Physical attack resistant
Physical attack resistant
Bullet resistant
Bullet/physical attack resistant
Bullet/physical attack resistant
Window Grade–high impact strength
Optically clear, enhanced abrasion
& UV resistance

GE Grade
LEXAN® 9030, 9034
DL 4630, DL 4634
N/A
LEXAN 90318 P.A.G.
LEXAN 9440
LEXAN 9600
LEXAN 1200
LEXAN SG 100
LEXAN MarGard
LEXGARD® MPC 375
LEXGARD MPC 500
LEXGARD RC 750
LEXGARD MP 750
LEXGARD MP 1000
LEXGARD SP 1250
Westlake Zelux
LEXAN FRA460,
FRA236

AtoHaas Grade
TUFFAK® A
N/A
TUFFAK A P-66
TUFFAK T
N/A
TUFFAK FI-8
TUFFAK XL
TUFFAK CM-2
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A

Lexan and Lexgard are registered trademarks of General Electric Corp.
TUFFAK is a registered trademark of AtoHaas.

Light Transmission (Initial)

LIGHT AND ENERGY TRANSMITTANCE

Clear

By allowing up to 90% of solar energy and 88% of visible
light through, clear Makrolon Polycarbonate Sheet is an
excellent glazing material for applications designed to
maximize solar gain. In areas of solar intensity where higher
shading or privacy is required, tinted materials may be used.

Gauge
3/32˝
1/8˝
3/16˝
1/4˝

Visible
87%
86%
84%
82%

Solar Energy
90%
89%
88%
86%

Bronze or Gray
Visible
50%
50%
50%
50%

Solar Energy
58%
58%
58%
58%

Technical information
TYPICAL Makrolon® GP POLYCARBONATE SHEET PROPERTIES
Property
General
Specific gravity
Water Absorption 24 hrs.
Refractive Index
Mechanical
Tensile Strength, Yield, .125˝
Tensile Strength, Ultimate
Tensile Modulus
Shear Strength
Compressive Strength
Flexural Strength at 5% Strain
Flexural Modulus .125˝
Izod Impact Notched .125˝
Rockwell Hardness
Gardner Impact 1/2˝ Diameter Dart .125˝
Instrumented Impact .125˝
Thermal
Heat Deflection Temperature 264 psi
Heat Deflection Temperature 68 psi
Coefficient of Thermal Expansion
Coefficient of Thermal Conductivity
Smoke Density
Shading Coefficient Clear .125˝
Shading Coefficient Gray/Bronze .125˝
Shading Coefficient Dark Gray .125˝
Brittle Temperature
Flammability
Horizontal Burn, AEB .125˝
Horizontal Burn, ATB .125˝
Self Ignition Temperature
Flash Ignition Temperature
UL 94 Clear ≥ .060˝
UL 94 Clear ≥ .250˝
Optical
Transmittance Clear .125˝
Haze Clear .125˝
Electrical
Dielectric Constant 10 Hz
Dielectric Constant 60 Hz
Volume Resistivity
Dissipation Factor 60 Hz
Dissipation Factor 1 MHz
Arc Resistance
Stainless Steel Strip Electrodes
Tungsten Electrodes

MAKROLON

Units

Test Method

1.2
0.15
1.586

%
-

ASTM D-792
ASTM D-570
ASTM D-542

9,000
9,500
345,000
6,000
12,500
13,500
345,000
12-16
118
>320
>45

psi
psi
psi
psi
psi
psi
psi
ft.lb/in of notch
R Scale
in.lbs
ft.lbs

ASTM D-638
ASTM D-638
ASTM D-638
ASTM D-732
ASTM D-695
ASTM D-790
ASTM D-790
ASTM D-256
ASTM D-785
ASTM D-5420
ASTM D-3763

270
280
3.75 x 10-5
1.35
68
1.02
.70
.58
-200

°F
°F
in/in/°F
BTU/hr/ft2/°F
°F

ASTM D-648
ASTM D-648
ASTM D-696
ASTM D-177
ASTM D-2843
ASHRAE
ASHRAE
ASHRAE
ASTM D-746

<1
<1
1070
800
V-2
V-0

in
min
°F
°F
-

ASTM D-635
ASTM D-635
ASTM D-1929
ASTM D-1929
UL 94
UL 94

>88
<1

%
%

ASTM D-1003
ASTM D-1003

2.96
3.17
8.2 x 1016
0.0009
0.010

ohm-cm
-

ASTM D-150
ASTM D-150
ASTM D-257
ASTM D-150
ASTM D-150

10-11
120

sec
sec

ASTM D-495
ASTM D-495

COMPETITIVE EDGE

DOCUMENTATION AND TECHNICAL SUPPORT

Bayer MaterialScience sets rigid raw material requirements
for its polycarbonate resins supplied by Bayer Corporation.
These materials, coupled with state-of-the-art production
and quality control technology, assure that the physical
properties of Makrolon Polycarbonate Sheet will meet or
exceed any directly competitive product on the market today.

Specific product information, warranty details, and further
information regarding proper fabrication and/or use of
materials can be received by contacting your local
Makrolon Polycarbonate Sheet distributor or by visiting
us at www.materialscience.bayer.com.

Makrolon® POLYCARBONATE
SHEET COMBUSTIBILITY

Bayer MaterialScience will not be responsible for the use of this information relative to
actual application. Users must make their own determination of its suitability for their
specific use. No warranty is made for the fitness of any product, and nothing herein
waives any of the seller’s conditions of sale.

Although the least combustible glazing material, Polycarbonate Sheet will ignite when exposed to an
ignition source over 800°F.

Environmental resistance of
Makrolon® polycarbonate sheet
Makrolon® POLYCARBONATE SHEET IS RESISTANT AT 70°F AND 0% STRAIN TO:
CHEMICALS:
Amyl Alcohol
Aluminum Chloride
Aluminum Sulfate
Ammonium Chloride
Ammonium Nitrate
Ammonium Sulfate
Antimony Trichloride
Arsenic Acid
Butyl Alcohol
Calcium Nitrate
Chlorinated Lime Paste
Chrome Alum

Chromic Acid (20%)
Citric Acid (40%)
Copper Chloride
Copper Sulfate
Formic Acid (10%)
Formalin (30%)
Glycerine
Heptane
Hydrochloric Acid (10%)
Hydrogen Peroxide (30%)
Hydrofluoric Acid (10%)
Isopropanol

Lactic Acid (20%)
Magnesium Chloride
Magnesium Sulfate
Manganese Sulfate
Mercuric Chloride
Nickel Sulfate
Nitric Acid (10%)
Nitric Acid (20%)
Oleic Acid
Oxalic acid
Pentane
Phosphoric Acid (10%)

Potassium Bromate
Potassium Bromide
Potassium Nitrate
Potassium Perchlorate
Potassium Permanganate
Potassium Persulfate
Potassium Sulfate
Silicone Oil
Silver Nitrate
Sodium Bicarbonate
Sodium Bisulfate
Sodium Carbonate

Sodium Chloride
Sodium Hypochlorite
Sodium Sulfate
Stannous Chloride
Sulfur
Sulfuric Acid (10%)*
Sulfuric Acid (50%)
Tartaric Acid (30%)
Zinc Chloride
Zinc Sulfate

*Sulfuric Acid at 1% attacks polycarbonate sheet

COMMON HOUSEHOLD MATERIALS Makrolon®
POLYCARBONATE IS RESISTANT TO:

PETROLEUM PRODUCTS Makrolon®
POLYCARBONATE SHEET IS RESISTANT TO:
Compressor Oil
Spindle Oil
Diesel Oil
Transformer Oil
Kerosene
Vacuum Pump Oil
Refined Oil
Note: Elevated temperature and/or strain significantly alters
resistance to industrial petroleum products.

CHEMICALS:
Borax
Cocoa
Cement
Chocolate
Cod Liver Oil
Cognac
Coffee
Detergents
Fish Oil
Fruit Syrup
Grapefruit Juice
Gypsum

Joy Liquid Detergent
Insulating Tape
Linseed Oil
Liquor
Milk
Mineral Water
Mustard
Olive Oil
Onions
Orange Juice
Paraffin Oil
Rapeseed Oil

Rum
Salad Oil
Salt Solution (10%)
Soap (Soft/Hard)
Table Vinegar
Tincture of Iodine (5%)
Tomato Juice
Vodka
Washing Soap
Water
Wine

LIMITED RESISTANCE AT 70°F AND 0% STRAIN TO:
Antifreeze
Calcium Chloride
Cyclohexanol
Ethylene Glycol

Hydrochloric Acid (conc.)
Milk or Lime (CaOH)
Nitric Acid (conc.)
Sulfuric Acid (conc.)

Makrolon® POLYCARBONATE SHEET IS NOT RESISTANT TO:
CHEMICALS:
Acetaldehyde
Acetic Acid (conc.)
Acetone
Acrylonitrile
Ammonia
Ammonium Fluoride
Ammonium Hydroxide
Ammonium Sulfide
Benzene
Benzoic Acid

Benzyl Alcohol
Brake Fluid
Bromobenzene
Butylic Acid
Carbon Tetrachloride
Carbon Disulfide
Carbolic Acid
Caustic Potash Sol. (5%)
Caustic Soda Sol. (5%)
Chloride

Chlorobenzene
Chlorothene
Cutting Oils
Cyclo Hexanone
Cyclohexene
Dimethyl Formamide
Ethane Tetrachloride
Ethylamine
Ethyl Ether
Ethylene Chlorohydrin

Formic Acid (conc.)
Freon (refrigerant/propellant)
Gasoline
Lacquer Thinner
Methyl Alcohol
Nitrobenzene
Nitrocellulose Lacquer
Ozone
Phenol
Phosphorus Hydroxy

Phosphorus Trichloride
Proplonic Acid
Sodium Sulfide
Sodium Hydroxide
Sodium Nitrate
Tetrahydronaphthalene
Thiophene
Toluene
Turpentine
Xylene

Makrolon® POLYCARBONATE SHEET IS DISSOLVED BY:
Chloroform, Cresol, Dioxane, Ethylene Dichloride,Methylene Chloride, Pyridine

EFFECTS OF MOISTURE ON Makrolon® POLYCARBONATE SHEET:
Makrolon Polycarbonate Sheet has good resistance to water up
to approximately 150°F. Above this temperature, the effect of
moisture is time-temperature related. Exposing Makrolon Polycar22

bonate Sheet to repeated steam cleaning or dishwashing can
create hydraulic crazing. The result can be a clouding of the
surface and ultimately a loss of physical strength properties.

Makrolon® polycarbonate sheet...
BROAD RANGE OF PRODUCTS FOR THE
MOST DEMANDING APPLICATIONS
From lofty barrel vault skylights exposed to extreme sunlight
to street level signs that require resistance to graffiti and
vandalism...from precision machined parts to the simple
toughness of domed playground windows, there is a
Makrolon® Polycarbonate Sheet product that's right for
your application.

Makrolon® AR Polycarbonate Sheet

Makrolon® GP Polycarbonate Sheet

Hygard® Laminates

is UV-stabilized and incorporates both economy and high
performance in every sheet. One attribute that sets it apart
from the competition is the UL 94 VO rating on gauges .220˝
and greater, making it cost effective in a wide range
of industrial and design applications.

offer unsurpassed protection from ballistic and
physical attack in bullet resistant and containment
glazing applications.

offers UV resistance, glass-like surface hardness, high
impact strength, and excellent chemical resistance,
making it an outstanding choice for flat, noncurved
machine guards.

Makrolon® SL Polycarbonate Sheet
is enhanced, UV resistance polycarbonate sheet that offers
exceptional weatherability. Superior impact strength and
formability makes this product an ideal choice for exterior
factory/plant glazing; guards used in outdoor equipment;
or other applications requiring increased weatherability and
UV resistance.

For detailed product or limited warranty
information on any Bayer MaterialScience sheet
product please call: 800/254-1707, or visit our
web site at www.materialscience.bayer.com.
23

For more information please contact
Bayer MaterialScience
customer service department
Phone: 800.254.1707
FAX: 800.457.3553
www.materialscience.bayer.com
E-mail: info@sheffieldplastics.com

Bayer MaterialScience
119 Salisbury Road
Sheffield, MA 01257
Toll Free: 800.254.1707
Fax: 800.457.3553
info@sheffieldplastics.com
www.materialscience.bayer.com

The manner in which you use and the purpose to which you put and utilize our products, technical
assistance and information (whether verbal, written or by way of production evaluations), including
any suggested formulations and recommendations are beyond our control. Therefore, it is
imperative that you test our products, technical assistance and information to determine to your
own satisfaction whether our products, technical assistance and information are suitable for your
intended uses and applications. This application-specific analysis must at least include testing to
determine suitability from a technical as well as health, safety, and environmental standpoint.
Such testing has not necessarily been done by us. Unless we otherwise agree in writing, all
products are sold strictly pursuant to the terms of our standard conditions of sale which are
available upon request. All information and technical assistance is given without warranty or
guarantee and is subject to change without notice. It is expressly understood and agreed that you
assume and hereby expressly release us from all liability, in tort, contract or otherwise, incurred in
connection with the use of our products, technical assistance, and information. Any statement or
recommendation not contained herein is unauthorized and shall not bind us. Nothing herein shall
be construed as a recommendation to use any product in conflict with any claim of any patent
relative to any material or its use. No license is implied or in fact granted under the claims
of any patent.
MAKFABGUIDE0412

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PT 042 Fabrication Guide

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