PT 042 Fabrication Guide

Fabrication Guide

Makrolon®polycarbonate sheet

3

Contents

Fabricating

Sawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Routing

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Shearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Laser Cutting

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Die Cutting

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Drilling

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Forming

Brake Bending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

Cold Bending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

Thermoforming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

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

Bonding/Fastening

Mechanical Fastening

. . . . . . . . . . . . . . . . . . . . . . . . . .14

Solvent Bonding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

Transfer Tape Bonding . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

Finishing

Sanding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

Jointing-Planing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

Solvent Polishing

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Hot Stamping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

Screen Printing

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Painting

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Paint and Ink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

Glazing Information

Installation Guidelines and Procedures

. . . . . . . . . . . . . . . . 18

Cleaning and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . .

19

Product Selector

Product Features

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Competitive Offsets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

Warranties

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Technical Information

Physical Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Environmental Resistance . . . . . . . . . . . . . . . . . . . . . . . 23

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

4

Gap between saw

blade and table–

minimize

Blade Makrolon®

Hold Down

Fence

Triple Chip Alternate

Tooth Design

Router Bit Suppliers:

Dino Saw Company

340 Power Ave.

Hudson, NY 12534

Tel: (518) 828-9942

www.dinosaw.com

Boshco Inc.

144-A Rangeway Road

North Billerica, MA 01862

Tel: (978) 667-1911

www.boshco.com

Onsrud Cutter

800 Liberty Drive

Libertyville, IL 60048

Tel: (800) 234-1560

www.onsrud.com

CIRCULAR SAWS

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.

Circular saws should be run in the speed range of 6000-

8000 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.

Fabricating

CIRCULAR SAW TROUBLESHOOTING

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

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

5

ROUTING

Routing produces a smooth edge on Makrolon Polycar-

bonate 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.

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.

BAND SAWS

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.

Knife

Edge Top Blade

Bed Blade

LASER CUTTING

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.

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.

Laser Cut Parts:

Laser Engineering Inc. Preco Laser Systems

444 North York Road 500 Laser Drive

Elmhurst, IL 60126 Somerset, WI 54025

Tel: (630) 530-0500 Tel: (715) 247-3285

www.laserengineering.com www.precolaser.com

Laser Cutting Equipment Supplier:

Preco Laser Systems

500 Laser Drive

Somerset, WI 54025

Tel: (715) 247-3285

www.precolaser.com

1˝ 8-12 teeth

per inch

BAND SAW BLADE DESIGN

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

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.

Makrolon®

Polycarbonate Sheet

Router Bit

Table

Fence

Feed Direction

Die Cutting Equipment Suppliers:

National Steel Rule Die Co. Atlas Die, Inc.

3580 Lightner Boulevard 2000 Middlebury Street

Vandalia, OH 45377 Elkhart, IN 46516

Tel: (937) 667-8407 Tel: (574) 295-0050

www.zedindustries.com www.atlasdie.com

Specialty Drill Bit Suppliers:

Craftics, Inc. FTM, Inc.

PO Box 91930 6160 Cobblestone Road

Albuquerque, NM 87199 Placerville, CA 95667

Tel: (505) 338-0005 Tel: (530) 626-1986

www.craftics.com www.thefabricatorssource.com

DIE CUTTING

Die cutting Makrolon®Polycarbonate Sheet in

gauges up to .080˝ thick is normally achieved utilizing the

following steps.

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:

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

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

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

2,000 2,000 lbs.

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˝).

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.

DRILLING

Makrolon Polycarbonate Sheet is easily drilled using ordinary

high-speed steel drill bits.

6

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 notch-

sensitive material, like most clear plastics. Recommended

drill speed is 350-1750 rpm.

30°

.030˝

15°

30°

15°

5°

.084˝

10°

10°-15°

.042˝

.020˝

.042˝

Upper Press Platen

Lower Press Platen

Reversed

Makrolon®

Polycarbonate Sheet

Plywood

Foam

Rubber

Backup

Pad

Steel

Rule

90°-188°

included

cutting-lip

angle

Clearance angle

0°-5° negative rake

15°

Facet Center Side

Bevel Bevel Bevel

CROSS SECTION-BLADE GRINDS

DRILL BIT DESIGN

Hole Dia. Drill Speed (RPM)

1/8˝ 1750

1/4˝ 1000-1500

1/2˝ 350-500

Fabricating cont’d.

7

1/8˝ 12.5˝

3/16˝ 18.7˝

1/4˝ 25.0˝

Note: Makrolon® AR Polycarbonate Sheet is recommended for flat

glazing only.

COLD BEND RADII

THERMOFORMING

Makrolon Polycarbonate Sheet can be thermoformed on

standard equipment. Vacuum forming, free blown forming,

and line bending are the most extensively used processes.

While most standard forming techniques can be used,

critical process modifications specific to polycarbonate are

necessary to ensure uniform and repeatable formed parts.

PREDRYING Makrolon®

POLYCARBONATE SHEET

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.

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.

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

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.

BRAKE BENDING

Makrolon®Polycarbonate Sheet can be brake bent to 90°

angles in gauges ≤.10 0˝. 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˝.

COLD BENDING

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).

Sheet Thickness (T)Minimum Radius (R)

THICKNESS 250°F 180°F

.093˝ 4 8

.118˝ 6 14

.150˝ 8 20

.177˝ 12 30

.236 24 50

Note: Makrolon®AR Polycarbonate Sheet is recommended for flat

glazing only.

DRYING TIME (HOURS)

Forming

HEATING CYCLE

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.

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.

O Heat source is removed and heated sheet is forced over

or into mold where vacuum is applied.

HELPFUL HINT:

OMakrolon 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.

8

SHADING OR SCREENING

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:

OUse 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.

OScreens can be installed permanently or placed loosely

above the sheet, depending on how much shading

is required.

HELPFUL HINTS:

OUse slow heating. This is particularly important with

heavier gauges in order to prevent gradient heating.

OAllow heat to reach uniformity at the center of

the sheet.

OThe heating rate may be reduced by lowering the

heat intensity or by moving the sheet farther away

from the heaters.

Forming cont’d.

9

Thermoforming Machines:

Brown Machine Plasti-Vac, Inc.

Division John Brown Plastics 214 Dalton Avenue

330 North Ross Street P.O. Box 5543

Beaverton, MI 48612 Charlotte, NC 28206

Tel: (517) 435-7741 Tel: (800) 438-4139

www.brownmachine.com www.pvi-plastivac.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

Thermoforming troubleshooting

PROBLEM POSSIBLE CAUSE SUGGESTED SOLUTION

Bubbles or blisters Too much moisture in sheet - Predry sheet for longer time period

- Check predry oven temperature

Pinholes or surface marks Vacuum holes too large - Use smaller diameter vacuum holes

Mark off Mold surface too smooth - Vapor hone or use extra fine emery

cloth to lightly abrade mold surface

Mold surface too rough - Preheat mold

Sheet pulls out of damping

frame during forming Sheet too cold to form - Heat sheet for longer time period

Non-uniform sag Uneven heating - Check heaters

- Screen “hot” areas

Incomplete part formation detail Sheet too cold - Heat sheet for longer time period

Inadequate vacuum - Check vacuum system for leakage

- Increase vacuum

Webbing Sheet too hot - Reduce heating cycle

Improper mold spacing - Redesign mold

- Use mechanical assist/bridging

10

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.

HELPFUL HINTS:

OKeep 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.

OUse vapor honed or fine sanded finishes.

OAvoid sharp corners to minimize stress.

OAvoid highly polished surfaces that can cause mark off.

OAlways preheat mold. Cold molds can create surface

defects and/or warped parts.

OIf mold temperature becomes too high during thermo-

forming runs, Makrolon Polycarbonate Sheet

could stick to the mold. It is recommended that the

mold temperature not exceed 260°F.

FORMING GUIDELINES

Sheet Temperature:

Typical: 340˚F-380˚F

Optimum: 350˚F-360˚F

Mold Temperature: 210˚F-260˚F

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.

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.

MOLDS

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.

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.

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.

Mold

3.00˝ Part

3.021˝

MOLD SHRINKAGE

Material Heat Transfer K Value

Rate Factor btu/hr/sf/f/ft

Aluminum 6190 130

Steel 1238 26

Aluminum filled epoxy 24-47 .52-.87

Plaster of Paris 8.29 .17

Epoxy 6.24 .13

Wood (maple) 4.48 .09

TYPICAL MOLD MATERIALS

THERMAL CONDUCTIVITY PROPERTIES

Forming cont’d.

1

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.

Forming with billow plug is often used to produce

thin-wall items with depth-to-diameter draw ratios

up to 1.5:1.

Air-slip forming is similar to vacuum snap-back

except that heated sheet is billowed up and

mold rises to meet it.

11

CLAMP

WORK

TABLE

MOLD

SHEET

VACUUM

FORCE

PLUG

CLAMP

VACUUM

BOX

VACUUM

MALE

MOLD

VACUUM

SHEET

MALE

MOLD

PLUG

CLAMP

HEATED

SHEET

FEMALE

MOLD

VACUUM DRAWS

SHEET AGAINST MOLD

AIR BLOWS SHEET UP

HEATED SHEET

FORCE

Drape forming over a male mold usually results in

better material distribution and depth-to-diameter

draw ratios.

HEATER

CLAMP

SHEET

VACUUM

WORK

TABLE

MALE

MOLD

Straight vacuum forming in a female mold is

recommended for low-profile parts where deep

draw is not a requirement.

FEMALE

MOLD

WORK

TABLE

HEATER

SHEET

VACUUM

HEATED SHEET

AIR

ENTERING VACUUM APPLIED

SHEET

MOLD

SHEET

2

34

HEATED SHEET

5

CLAMP

6

CLAMP

Heater

Sag

Electric

Eye

Clamp

Frame

Vacuum

Box

Vacuum Line

Apply Vacuum

Makrolon®

Polycarbonate

Sheet

Heat Source

Clamp

Frame

Air

Box

Air Inlet

Sag

Electric

Eye

Air Pressure

Microswitch

12

BLOWN DOME FORMING

DRAWN DOME FORMING

REGISTRATION FORMING

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.

FREE BLOWN BILLOW FORMING OF DOME

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).

PROCEDURE:

OPreheat all clamps and tooling (240°F-260°F).

OPredry Makrolon Polycarbonate Sheet in air

circulating oven at 250°F. (See page 7 for

recommended drying times.)

OPlace Makrolon Polycarbonate Sheet in

clamping frame of thermoforming machine.

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

ORemove heat source.

OLower pressure box to seal air supply pressure.

OApply air pressure. Initial air pressure is high, and as

dome is created, air pressure is reduced.

OWhen overall height is achieved, maintain positive

air pressure until part cools.

OBe sure air source is properly filtered and uniformly

dispersed for even formation of dome.

OUtilize electric eye designs or microswitches to

assure consistent product.

OWhen dome reaches electric eye, set height. The

eye controls air pressure through a solenoid valve to

control cooling.

ORemove and trim.

FREE DRAWN VACUUM DOME FORMING

Follow steps involved in vacuum thermoforming,

including predrying.

PROCEDURE:

OPlace sheet in clamping frame of thermoforming

machine.

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

ORemove heat source.

OApply vacuum seal box and apply vacuum pressure.

OUse electric eye or microswitch to assure consistency of

depth of dome.

ORetain small amount of vacuum pressure until dome

sets up.

ORemove and trim.

Forming cont’d.

13

DRAPE FORMING

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.

PROCEDURE:

OPredrying Makrolon Polycarbonate Sheet may

not be necessary.

OBring to forming temperature of about 300°F-320°F in

the oven.

ORemove parts and immediately place over a male mold

covered with felt.

OApply pressure until cool.

STRIP HEATING Makrolon®

POLYCARBONATE SHEET

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.

PROCEDURE:

ORemove protective masking in bend area.

ORegulate nichrome heat source to 340°F-365°F maximum.

OPlace sheet over heat source at bend area.

OAllow heat to soften material–time depends on gauge.

ORemove sheet and make desired bend on wood or heavy

fabric-covered aluminum fixture.

OBend immediately–polycarbonate sets up quickly.

OAllow 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.

Pressure Frame

Mold

Pressure Frame

Makrolon®

Polycarbonate

Sheet

Makrolon

Polycarbonate

Sheet

Felt Covering for Mold

Strip Heaters:

FTM Inc. C.R. Clark & Co.

6160 Cobblestone Road 1272 Aquila Loop

Placerville, CA 95667 Celebration, FL 34747

Tel: (530) 626-1986 Tel: (800) 676-7133

www.thefabricatorssource.com www.crclark.com

Craftics, Inc.

PO Box 91930

Albuquerque, NM 87199

Tel: (505) 338-0005

www.craftics.com

HEAT BENDING DEVICE

3/4˝

Transite

approx.

6˝ wide

Nichrome

resistance

wire (or

Calrod

type

heater)

Rheostat

for temp.

control

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.

DRAPE FORMING

OAvoid bending short tabs on wide parts; warping

may occur.

OFor thicker gauge sheet, use two-sided heating. (Repeated

turning with one-side heating may also achieve sufficient

heat penetration.)

OThicker gauge sheet (above 1/8˝) can be grooved with

a 1/16˝ radius to allow sharper bends.

STRIP HEATING TROUBLESHOOTING

PROBLEM: Bubbles in bent area

POSSIBLE CAUSE: Too much heat

SUGGESTED SOLUTION: Lower heat source

14

Adhesive Suppliers:

Industrial Polychemical Pacer Tech Industrial Hartel Enterprises Lord Corp.

Weld-On Adhesives 9420 Santa Anita Ave. 12970 Branford St., Suite F 2000 West Grandview Blvd.

17109 South Main Street Rancho Cucamonga, CA 91730 Pacoima, CA 91331 Erie, PA 16514

Gardena, CA 90247 Tel: (800) 538-3091 Tel: (818) 767-0861 Tel: (814) 868-3611

Tel: (800) 421-2677 www.supergluecorporation.com www.lord.com

www.ipscorp.com

Dow-Corning Corporation General Electric Company Ciba Specialty Chemicals Performance Polymers

3901 South Saginaw 260 Hudson River Road 4917 Dawn Avenue

Midland, MI 48640 Waterford, NY 12188 East Lansing, MI 48823

Tel: (989) 496-4000 Tel: (518) 237-3330 Tel: (800) 367-8793

www.dowcorning.com www.gesilicones.com www.loctite.com

Oversized

Hole

Resilient

Washer

Resilient

Washer

Makrolon®

polycarbonate

sheet

NEEDLE APPLICATOR

Bonding and fastening

MECHANICAL FASTENING

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.

SOLVENT BONDING

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.

It should be noted that solvent bonding will significantly

reduce the strength of polycarbonate.

PROCEDURE:

OSmaller 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.

OFor bonding larger items, immerse the surfaces to be

joined in the solvent until the material is softened.

OClamp them in position and hold until the bond is set.

HELPFUL HINTS:

OEdges must be clean and free from dirt.

OSurfaces should be smooth and properly aligned.

OApply 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.

4. Joint cure time is somewhat longer than acrylic. Be sure

to retain fixture pressure until the joint is solid.

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.

15

WELDING

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 recom-

mendations on section and joint design.

TRANSFER TAPE BONDING

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.

PROCEDURE:

OBend a small return on the appropriate part to be

fastened approximately the width of the transfer tape.

OClean tape contact areas with 50/50 isopropyl

alcohol-water mixture.

OApply transfer tape to the return.

ORemove tape masking and press the part into place.

HELPFUL HINTS:

ORolling the bonded area with a small wood or rubber

roller improves bond strength.

OA nonstick slip sheet is useful for proper positioning of

large or hard to handle parts.

OPeel strength of long, lineal bonded areas can be

increased with the addition of a mechanical fastener at

both ends of the bond.

Transfer Tape Suppliers:

3M/Industrial Specialties Division St. Gobain Performance Plastics

3M Center, Bldg. 220-7E-01 1 Sealant Park

St. Paul, MN 55144-1000 Granville, NY 12832

Tel: (800) 227-5085 Tel: (518) 642-2200

www.3m.com/us/mfg_industrial/adhesives/ www.nortonfoam.com

Ultrasonic Welding Equipment:

Branson Ultrasonics Corp.

41 Eagle Road, Suite 1

Danbury, CT 06813-1961

Tel: (203) 796-0400

www.bransonultrasonics.com

ADHESIVE JOINS MAKROLON COMMENTS COLOR 1-OR 2-PART APPLICATION SETUP CURE SUPPLIER

SHEET TO SYSTEM METHOD TIME TIME

Methylene Makrolon - Clear Solvent Clear One Flow 20 sec. 48 hrs Chemical

Chloride Polycarbonate Sheet - High tensile @ 75°F Supply House

strength products

Acrylic - Low-impact

resistance

Weld-On Series Makrolon - Various viscosities Clear One Flow 1 min. 24 hrs. IPS/Weld-On

Polycarbonate Sheet offering quick

bonds

Butyrate

Urethane Virtually Anything - Clear, flexible Hartel

high-impact bond 5 hrs. Enterprises, Inc.

- Excellent peel Clear Two Flow 8 hrs. @ 150°F

strength @ 75°F or 7 days Formulated

- Excellent shear @ 75°F Systems Group

strength

RTV Silicone Metal/Plastic/Wood - Excellent heat Various One Tubes, Caulkers 60 min. 24 hrs. Dow-Corning

resistance Colors @ 75°F

- Good thermal GE Silicones

expansion

Makrolon®POLYCARBONATE SHEET ADHESIVE GUIDE

16

SANDING

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 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

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.

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.

HOT STAMPING

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.

SCREEN PRINTING

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.

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.

Finishing

17

PAINTING

Many paint systems are available for Makrolon®Polycar-

bonate 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.

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.

A number of companies market paint systems for Makrolon

Polycarbonate Sheet and provide technical advice on

application.

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.

NOTES ON Makrolon®AR

POLYCARBONATE SHEET

Coated sides of Makrolon AR Polycarbonate

Sheet cannot be painted because of the abrasion-

resistant 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.

Hot Stamping Foil Suppliers:

Transfer Print Foils, Inc. Foilmark

9 Cotters Lane 40 Melville Park Road

East Brunswick, NJ 08816 Melville, NY 11747

Tel: (908) 238-1800 Tel: (800) 645-9177

(800) 235-3645 www.foilmark.com

hmt.com/holography.TPF

Crown Roll Leaf, Inc.

91 Illinois Ave.

Paterson, NJ 07503

Tel: (800) 631-3831

www.crownrollleaf.com

Screen Print Ink Supplier:

NazDar

1087 N. Northbranch Street

Chicago, IL 60622

Tel: (800) 736-7636

www.nazdar.com

Paint Suppliers:

Spraylat Corporation Red Spot Paint & Varnish Co., Inc.

716 South Columbus Avenue 1107 E. Louisiana Street

Mt.Vernon, NY 10550 Evansville, IN 47711

Tel: (914) 699-3030 Tel: (800) 457-3544

(800) 336-1936 www.redspot.com

www.spraylat.com

Mathews Paint Company

8201100 Street

Pleasant Prairie, WI 53158

Tel: (800) 323-6593

www.mathewspaint.com

Short Dimension (Inches)

Windload (PSF)

50

40

30

20

10

0

Wind Velocity MPH

84 96

1/8"

3/16" 1/4"

3/8"

1/2"

24 30 4236485460667278

120

80

100

60

WIND LOAD PERFORMANCE

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.

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.

18

Glazing information

Product Product Manufacturer

Type Name

Silicone Dow 795 Dow-Corning Corp

Dow 999 Midland, MI

Trademate® (517) 496-4000

Silicone Silpruf® General Electric Co.

Construction Waterford, NY

1200® (800) 255-8886

Silicone Spectrem Tremco

Columbus, OH

(800) 321-7906

Gasket EPDM (60,70D) Tremco

Columbus, OH

(800) 321-6357

Tape 440 Tremco

Beechwood, OH

(800) 321-7906

Gasket/Tape Norrene®Foam Norton Company

V-2100 Urethane Granville, NY

(518) 642-2200

Butyl Tape Isocryl 5600 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

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:

OFormula 409®

OTop Job, Joy®

OPalmolive Liquid®

OWindex 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

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.

18

19

EXPANSION ALLOWANCES–EDGE ENGAGEMENTS

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

COMPARATIVE EXPANSION RATES

Material in./in. °F

Glass .0000050

Makrolon®

Polycarbonate Sheet .0000375

Aluminum .0000129

Steel .0000063

Acrylic .0000410

20

LIGHT AND ENERGY TRANSMITTANCE

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.

Product selector

Product Features

Makrolon® Makrolon® Makrolon® Makrolon®

Makrolon®

Privacy Makrolon®

GP SN AR SL (SunLife) FI Patterns CG Hygard®

Superior Impact Strength        

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 Description GE Grade AtoHaas Grade

Makrolon®GP General purpose grade for fabrication LEXAN® 9030, 9034 TUFFAK®A

and glazing DL 4630, DL 4634

Makrolon®GP Matte Matte texture for privacy glazing N/A N/A

Makrolon®GP Pebble Pebble patterns for privacy glazing LEXAN 90318 P.A.G. TUFFAK A P-66

Makrolon®FD FDA compliant material LEXAN 9440 TUFFAK T

Makrolon®FI Flame inhibiting grade LEXAN 9600 N/A

Makrolon®FI Flame inhibiting LEXAN 1200 TUFFAK FI-8

Makrolon®SL Thermoformable enhanced UV resistance LEXAN SG 100 TUFFAK XL

Makrolon®AR Abrasion & UV resistance LEXAN MarGard TUFFAK CM-2

Makrolon®CG 375 Physical attack resistant LEXGARD®MPC 375 N/A

Makrolon®CG 500 Physical attack resistant LEXGARD MPC 500 N/A

Makrolon®CG 750 Physical attack resistant LEXGARD RC 750 N/A

Hygard®750 Bullet resistant LEXGARD MP 750 N/A

Hygard®1000 Bullet/physical attack resistant LEXGARD MP 1000 N/A

Hygard®1250 Bullet/physical attack resistant LEXGARD SP 1250 N/A

Makrolon®WG Window Grade–high impact strength Westlake Zelux N/A

Makrolon®TG Optically clear, enhanced abrasion LEXAN FRA460, N/A

& UV resistance FRA236

Lexan and Lexgard are registered trademarks of General Electric Corp.

TUFFAK is a registered trademark of AtoHaas.

Light Transmission (Initial)

Clear Bronze or Gray

Gauge Visible Solar Energy Visible Solar Energy

3/32˝ 87% 90% 50% 58%

1/8˝ 86% 89% 50% 58%

3/16˝ 84% 88% 50% 58%

1/4˝ 82% 86% 50% 58%

21

COMPETITIVE EDGE

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.

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.

Technical information

TYPICAL Makrolon®GP POLYCARBONATE SHEET PROPERTIES

Property MAKROLON Units Test Method

General

Specific gravity 1.2 - ASTM D-792

Water Absorption 24 hrs. 0.15 % ASTM D-570

Refractive Index 1.586 - ASTM D-542

Mechanical

Tensile Strength, Yield, .125˝ 9,000 psi ASTM D-638

Tensile Strength, Ultimate 9,500 psi ASTM D-638

Tensile Modulus 345,000 psi ASTM D-638

Shear Strength 6,000 psi ASTM D-732

Compressive Strength 12,500 psi ASTM D-695

Flexural Strength at 5% Strain 13,500 psi ASTM D-790

Flexural Modulus .125˝ 345,000 psi ASTM D-790

Izod Impact Notched .125˝ 12-16 ft.lb/in of notch ASTM D-256

Rockwell Hardness 118 R Scale ASTM D-785

Gardner Impact 1/2˝ Diameter Dart .125˝ >320 in.lbs ASTM D-5420

Instrumented Impact .125˝ >45 ft.lbs ASTM D-3763

Thermal

Heat Deflection Temperature 264 psi 270 °F ASTM D-648

Heat Deflection Temperature 68 psi 280 °F ASTM D-648

Coefficient of Thermal Expansion 3.75 x 10-5 in/in/°F ASTM D-696

Coefficient of Thermal Conductivity 1.35 BTU/hr/ft2/°F ASTM D-177

Smoke Density 68 - ASTM D-2843

Shading Coefficient Clear .125˝ 1.02 - ASHRAE

Shading Coefficient Gray/Bronze .125˝ .70 - ASHRAE

Shading Coefficient Dark Gray .125˝ .58 - ASHRAE

Brittle Temperature -200 °F ASTM D-746

Flammability

Horizontal Burn, AEB .125˝ <1 in ASTM D-635

Horizontal Burn, ATB .125˝ <1 min ASTM D-635

Self Ignition Temperature 1070 °F ASTM D-1929

Flash Ignition Temperature 800 °F ASTM D-1929

UL 94 Clear ≥ .060˝ V-2 - UL 94

UL 94 Clear ≥ .250˝ V-0 - UL 94

Optical

Transmittance Clear .125˝ >88 % ASTM D-1003

Haze Clear .125˝ <1 % ASTM D-1003

Electrical

Dielectric Constant 10 Hz 2.96 - ASTM D-150

Dielectric Constant 60 Hz 3.17 - ASTM D-150

Volume Resistivity 8.2 x 1016 ohm-cm ASTM D-257

Dissipation Factor 60 Hz 0.0009 - ASTM D-150

Dissipation Factor 1 MHz 0.010 - ASTM D-150

Arc Resistance

Stainless Steel Strip Electrodes 10-11 sec ASTM D-495

Tungsten Electrodes 120 sec ASTM D-495

DOCUMENTATION AND TECHNICAL SUPPORT

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

Although the least combustible glazing material, Polycar-

bonate Sheet will ignite when exposed to an

ignition source over 800°F.

22

Makrolon®POLYCARBONATE SHEET IS RESISTANT AT 70°F AND 0% STRAIN TO:

CHEMICALS:

Amyl Alcohol Chromic Acid (20%) Lactic Acid (20%) Potassium Bromate Sodium Chloride

Aluminum Chloride Citric Acid (40%) Magnesium Chloride Potassium Bromide Sodium Hypochlorite

Aluminum Sulfate Copper Chloride Magnesium Sulfate Potassium Nitrate Sodium Sulfate

Ammonium Chloride Copper Sulfate Manganese Sulfate Potassium Perchlorate Stannous Chloride

Ammonium Nitrate Formic Acid (10%) Mercuric Chloride Potassium Permanganate Sulfur

Ammonium Sulfate Formalin (30%) Nickel Sulfate Potassium Persulfate Sulfuric Acid (10%)*

Antimony Trichloride Glycerine Nitric Acid (10%) Potassium Sulfate Sulfuric Acid (50%)

Arsenic Acid Heptane Nitric Acid (20%) Silicone Oil Tartaric Acid (30%)

Butyl Alcohol Hydrochloric Acid (10%) Oleic Acid Silver Nitrate Zinc Chloride

Calcium Nitrate Hydrogen Peroxide (30%) Oxalic acid Sodium Bicarbonate Zinc Sulfate

Chlorinated Lime Paste Hydrofluoric Acid (10%) Pentane Sodium Bisulfate

Chrome Alum Isopropanol Phosphoric Acid (10%) Sodium Carbonate

*Sulfuric Acid at 1% attacks polycarbonate sheet

Environmental resistance of

Makrolon®polycarbonate sheet

COMMON HOUSEHOLD MATERIALS Makrolon®

POLYCARBONATE IS RESISTANT TO:

CHEMICALS:

Borax Joy Liquid Detergent Rum

Cocoa Insulating Tape Salad Oil

Cement Linseed Oil Salt Solution (10%)

Chocolate Liquor Soap (Soft/Hard)

Cod Liver Oil Milk Table Vinegar

Cognac Mineral Water Tincture of Iodine (5%)

Coffee Mustard Tomato Juice

Detergents Olive Oil Vodka

Fish Oil Onions Washing Soap

Fruit Syrup Orange Juice Water

Grapefruit Juice Paraffin Oil Wine

Gypsum Rapeseed Oil

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.

LIMITED RESISTANCE AT 70°F AND 0% STRAIN TO:

Antifreeze Hydrochloric Acid (conc.)

Calcium Chloride Milk or Lime (CaOH)

Cyclohexanol Nitric Acid (conc.)

Ethylene Glycol Sulfuric Acid (conc.)

Makrolon®POLYCARBONATE SHEET IS NOT RESISTANT TO:

CHEMICALS:

Acetaldehyde Benzyl Alcohol Chlorobenzene Formic Acid (conc.) Phosphorus Trichloride

Acetic Acid (conc.) Brake Fluid Chlorothene Freon (refrigerant/propellant) Proplonic Acid

Acetone Bromobenzene Cutting Oils Gasoline Sodium Sulfide

Acrylonitrile Butylic Acid Cyclo Hexanone Lacquer Thinner Sodium Hydroxide

Ammonia Carbon Tetrachloride Cyclohexene Methyl Alcohol Sodium Nitrate

Ammonium Fluoride Carbon Disulfide Dimethyl Formamide Nitrobenzene Tetrahydronaphthalene

Ammonium Hydroxide Carbolic Acid Ethane Tetrachloride Nitrocellulose Lacquer Thiophene

Ammonium Sulfide Caustic Potash Sol. (5%) Ethylamine Ozone Toluene

Benzene Caustic Soda Sol. (5%) Ethyl Ether Phenol Turpentine

Benzoic Acid Chloride Ethylene Chlorohydrin Phosphorus Hydroxy Xylene

Makrolon®POLYCARBONATE SHEET IS DISSOLVED BY:

Chloroform, Cresol, Dioxane, Ethylene Dichloride,Methylene Chloride, Pyridine

EFFECTS OF MOISTURE ON Makrolon®POLYCARBONATE SHEET:

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 has good resistance to water up

to approximately 150°F. Above this temperature, the effect of

moisture is time-temperature related. Exposing Makrolon Polycar-

23

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®GP Polycarbonate Sheet

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.

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.

Makrolon®polycarbonate sheet...

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.

Makrolon®AR Polycarbonate Sheet

offers UV resistance, glass-like surface hardness, high

impact strength, and excellent chemical resistance,

making it an outstanding choice for flat, noncurved

machine guards.

Hygard®Laminates

offer unsurpassed protection from ballistic and

physical attack in bullet resistant and containment

glazing applications.

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.

Bayer MaterialScience

119 Salisbury Road

Sheffield, MA 01257

Toll Free: 800.254.1707

Fax: 800.457.3553

info@sheffieldplastics.com

www.materialscience.bayer.com

Bayer, the Bayer Cross and Makrolon® are registered trademarks of Bayer MAKFABGUIDE0412

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

PT 042 Fabrication Guide

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