Polycarbonate (PC) is a high-performance transparent engineering thermoplastic primarily produced through the polymerization of bisphenol A (BPA) and phosgene (COCl₂).
Renowned for its exceptional impact resistance, optical clarity (up to 90% light transmission), thermal stability, and excellent processability, polycarbonate is widely used across industries such as safety equipment, automotive components, bullet-resistant glazing, medical devices, and electronics.
Its light weight and durability make PC an ideal substitute for glass and certain metals in demanding applications.

Chemical and Structural Overview

Polycarbonate consists of repeating carbonate linkages (–O–(C=O)–O–) within its polymer backbone.
It is typically synthesized via the reaction of bisphenol A (BPA) with phosgene or diphenyl carbonate (DPC).
This molecular configuration provides a unique balance between transparency, mechanical strength, thermal resistance, and ease of molding, establishing PC as one of the most versatile engineering polymers available.

Key Physical and Chemical Properties

Optical Transparency: Up to ~90% light transmittance, comparable to glass
Density: ~1.20–1.22 g/cm³ (lighter than glass)
Impact Strength: Up to 200× stronger than glass of equivalent thickness
Heat Resistance: Maintains mechanical integrity up to 120–130 °C
Chemical Resistance: Resistant to oils and greases; sensitive to strong organic solvents (e.g., acetone, toluene)
Processing Methods: Suitable for injection molding, extrusion, blow molding, and thermoforming

Major Applications

Automotive Industry: Headlamp lenses, impact-resistant glazing, interior panels
Construction: Polycarbonate sheets for skylights, greenhouses, and roofing panels
Electronics: CD/DVD discs, equipment housings, LED covers, and electrical insulators
Medical Field: Durable and sterilizable laboratory ware, device components
Personal Protection: Helmets, face shields, and safety goggles
Specialty Packaging: Reusable bottles and high-impact containers

Advantages

Excellent optical clarity with high transparency
Superior impact and mechanical strength
Lightweight alternative to glass and metal
Outstanding dimensional stability and heat resistance
Self-extinguishing behavior; can be formulated with flame retardants
Long-term durability in harsh environmental conditions

Limitations

Scratch-sensitive surface — often requires hard coating for optical applications
UV degradation — may yellow or become brittle under sunlight without stabilizers
Higher cost compared to commodity plastics (PE, PP)
Moderate resistance to aggressive solvents such as ketones and aromatics

Safety and Storage Guidelines

Store in a cool, dry, well-ventilated area, away from direct sunlight
Avoid exposure to strong solvents (acetone, toluene, benzene)
Use industrial ventilation and protective masks during thermal processing (injection/extrusion)
Keep materials sealed to prevent moisture absorption prior to molding
Ensure workplace ventilation to avoid buildup of fumes from additives during processing

Summary

Polycarbonate (PC) offers a unique combination of transparency, strength, and versatility, making it a preferred choice in industries that demand both performance and aesthetics.
Its adaptability, toughness, and design flexibility have established it as one of the most valuable engineering plastics in the modern industrial landscape.