Our polycarbonate (also known as Lexan®) is perfect for high-impact applications, instrument panel covers, insulation applications, and fittings. It’s an incredibly versatile, formable material that is well-loved in the robotics and automation industries.

  • Available thicknesses are .118″, .177″, and .220″
  • CNC routed plastic (+/- .005″ cutting tolerance)
  • 2-4 day lead time before shipping
  • USA sourced

Custom Lexan® parts starting from $29 per order

High Voltage Insulation

What is Polycarbonate?

This impressively tough and transparent material can withstand high impact over a wide range of temperatures, has a high heat deflection temperature, and has a high modulus of elasticity, making it a great fit for construction applications such as windows, skylights, and roof domes. Of course, that’s only an extremely small view into what polycarbonate is capable of in the industry.

Polycarbonate / Lexan® material absorbs very little moisture and has high-voltage insulating properties. This makes it ideal for use in electrical and electronic components. Its transparency also makes it a superior option for structural applications that require, or otherwise would like, healthy sightlines.

Available Services:

What can you make with Polycarbonate?

Polycarbonate is commonly used in anti-ballistic panels (aka bulletproof glass). If that doesn’t stand testament to its impact absorption, we’re not sure what else would. If you still need more convincing, it’s also got a lot of other great stuff:

  • Unmatched clarity
  • Very low moisture absorption
  • Excellent thermal stability
  • Can be bent and formed
  • High tensile, shear, and flexural strength
  • Low deformation under load
  • Low coefficient of thermal expansion

This basically just means that polycarbonate thermoplastic is an absolutely resilient, powerful beast that won’t quit out on your projects.

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Material Details

.118″ Polycarbonate

Advertised Thickness .118″ | 3.0mm
Gauge N/A
Thickness Tolerance Positive .006″
Thickness Tolerance Negative .006″
Cutting Process CNC Router
Cut Tolerance .005″
Top/Bottom Finish Identical both sides
Sourced from USA
Available Operations
Deburring No
Bending Yes
Countersinking No
Tapping Yes
Anodizing No
Plating No
Powder Coating No
Hardware No
Tumbling No
Design Considerations
Min Part Size 1″ x 2″
Max Part Size 44″ x 30″
Min Hole Size (CNC Bit Size) .125″
Min Bridge Size .118″
Min Hole to Edge Size .035″
Tab and Slot Tolerance .010″
Min Bend Part Size .375″ x 1.5″
Max Bending Flat Part Size 44″ x 30″
Min Flange Length (Before Bend/Flat Pattern) 90° or less (obtuse) .368″
Min Flange Length (After Bend) 90° or less (obtuse) N/A
Max Bend Length 44″
Die Width .472″
Effective Bend Radius @ 90° .040″
Max Bend Angle 90°
Bend Angle Tolerance (bend length up to 24″) +/- 3 degrees
Bend Angle Tolerance (bend length over 24″) +/- 4 degrees
Bend Deduction @ 90° .1950″
K Factor .33
Bend Relief Depth .178″
Minimum Joggle BL2BL @90 Max Flange .400″
Maximum Joggle @90 Max Flange 3.750″
Smallest Tap M4 x 0.7
Largest Tap M10 x 1.5
Min Flat Part Size Tapping 1″ x 1.5″
Max Flat Part Size Tapping 36″ x 46″
Tapping Min Hole to Edge .059″
Tapping Min Hole Center to Material Edge Tap hole size/2 + .059″
Density 75 lb/ft^3
Tensile Strength (Ultimate) 9.5 ksi
Tensile Strength (Yield) 9.0 ksi
Shear Strength 10 ksi
Shear Modulus 120 ksi
Fatigue Strength 1.0 ksi
Flexural Modulus 330 ksi
Flexural Strength 13 ksi
Rockwell Hardness 68
Elongation at Break 110%
Elastic Modulus 340 ksi
Poisson’s Ratio .38
Comprehensive (Crushing) Strength 12 ksi
Thermal Conductivity 0.11 BTU/h-ft-°F
Maximum Temp (Decomposition) 890 °F
Magnetic N0

Our polycarbonate is guaranteed

We guarantee awesome quality parts. If you’re not 100% happy, we’ll give you a refund or remake on the spot – no questions, no hassle.

Plastic, composite, and wood materials cut on our CNC routers and waterjets will have small tabs.

These tabs hold your parts in place while being cut to ensure the best accuracy possible. Click below to learn what to expect and how to best design with these tabs in mind.

Start your first SendCutSend project today!

Upload your CAD design or use our parts builder and get a free instant quote on your custom laser cut parts, all delivered to your door in a matter of days.

No CAD File? No Problem! Send your sketch or template to our Design Services team.

We proudly use hardware by PEM

Flush stud, M8 x 1.25, .472" Zinc plus Clear Chromate

Thread SizeM8 x 1.25
Hole size in sheet (+0.003/-.0.000).315″
Minimum sheet thickness0.94″
Maximum sheet thickness.347″
Fastener materialSteel
Minimum distance hole C/L to edge0.378″
When determining the distance between two or more fasteners, you can calculate the distance by the formula, C/L to edge + 1/2 the diameter of the second mounting hole..535″
Recommended panel materialSteel/Aluminum
Coating typeZinc
Aluminum material ranges (5052, 6061, 7075)0.100″-0.250″
Steel material ranges (CRS, HRPO, HR)0.104″-0.250″

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We proudly use hardware by PEM

Flush Standoff, 4-40, .250" Zinc plus Clear Chromate

Thread Size4-40 x .250″
Hole size in sheet (+0.003/-.0.000).168″
Minimum sheet thickness0.040″
Maximum sheet thickness.125″
Fastener materialSteel
Minimum distance hole C/L to edge0.230″
When determining the distance between two or more fasteners, you can calculate the distance by the formula, C/L to edge + 1/2 the diameter of the second mounting hole..314″
Recommended panel materialSteel/Aluminum
Coating typeZinc
Aluminum material ranges (5052, 6061, 7075)0.040″-0.125″
Steel material ranges (CRS, HRPO, HR)0.048″-0.119″