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Polycarbonate(FDM)High-Performance Engineering Thermoplastic for Demanding Applications

Polycarbonate (PC) is an exceptional engineering thermoplastic renowned for its superior impact strength, heat resistance, and dimensional stability. With an impressive heat deflection temperature up to 143°C and outstanding toughness, PC delivers unmatched performance for functional prototypes, end-use parts, and manufacturing tooling that require the highest levels of mechanical integrity and thermal stability.

Tensile Strength
40 MPa
Flexural Modulus
2006 MPa
HDT
138 °C
Technology
FDM
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FDM material

Polycarbonate overview

Stratasys FDM Polycarbonate represents the pinnacle of thermoplastic performance for additive manufacturing. This advanced engineering material combines exceptional mechanical properties with superior thermal stability, making it the go-to choice for applications where standard thermoplastics fall short. PC's unique molecular structure delivers unparalleled impact resistance while maintaining excellent dimensional accuracy and surface finish. Its broad chemical resistance and ability to withstand continuous use temperatures up to 120°C make it ideal for functional parts that must perform in challenging environments. Whether you're creating aerospace components, automotive parts, or industrial tooling, Polycarbonate provides the reliability and performance demanded by the most critical applications.

Polycarbonate FDM cube sample showing high-performance thermoplastic properties
Why manufacture with Polycarbonate

Polycarbonate combines exceptional impact resistance - superior to standard thermoplastics and high heat deflection temperature up to 143°c for demanding thermal environments, delivering outstanding dimensional stability with minimal thermal expansion for demanding applications. From rapid prototyping to production runs, teams rely on Polycarbonate to maintain tight tolerances while reducing assembly complexity through consolidated part designs.

FDM Production Technology

Polycarbonate maximizes FDM strength capabilities with 89 MPa tensile strength and 127°C heat deflection temperature, delivering the highest mechanical performance of standard engineering thermoplastics. The Stratasys Fortus system's 360°C extrusion temperature ensures complete polymer fusion, creating parts with exceptional layer adhesion and isotropic strength approaching injection-molded properties. PC's superior impact resistance and optical clarity make it ideal for automotive lighting prototypes, medical device housings, and aerospace components. The material's biocompatibility certification and sterilization compatibility enable functional medical prototypes while maintaining dimensional stability through autoclave cycles.

Build Volume

914 × 610 × 914 mm

Lead Time

2-4 business days

Layer Height

0.25 mm

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Applications & field work

Where Polycarbonate excels

Stratasys FDM Polycarbonate delivers the highest impact resistance and heat deflection temperature (143°C) of standard FDM thermoplastics, making it the material of choice for functional prototypes and end-use parts requiring exceptional durability. Unlike brittle high-temp materials, PC maintains toughness even under repeated stress.

The material's superior dimensional stability and low moisture absorption enable tight-tolerance parts that maintain accuracy in varying environmental conditions. With excellent electrical insulation properties and broad chemical resistance, PC serves applications from automotive under-hood components to medical device housings.

Forge Labs' Fortus systems with heated build chambers ensure optimal layer adhesion and minimal warpage, critical for large structural parts. Our breakaway support material allows complex geometries while maintaining the pristine surface finish required for functional testing and assembly validation.

Mechanical

Tensile Strength, Yield (XZ Axis): 40 MPa

ASTM D638 - 57.9 MPa tensile
Thermal

Heat Deflection Temperature @ 66 psi: 138 °C

HDT 143°C @ 0.45 MPa
Physical

Specific Gravity: 1.2

Electrical

Volume Resistivity: 6.0E13 - 2.0E14 ohm-cm

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Industry applications for Polycarbonate

From automotive dashboards to aerospace fixtures, Polycarbonate enables functional parts that withstand real-world conditions. Explore how industries leverage this engineering thermoplastic.

Polycarbonate's impact resistance and heat stability make it ideal for automotive applications requiring both structural integrity and aesthetic quality. The material withstands dashboard temperatures up to 120°C while maintaining dimensional accuracy.

Key Applications

  • Dashboard components and instrument clusters
  • HVAC ducting and ventilation systems
  • Headlight housings and lens prototypes
  • Structural brackets and mounting components

Performance Data

Maintains impact strength of 761 J/m (unnotched) after 500 thermal cycles from -40°C to 120°C, exceeding automotive interior requirements.

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PC's biocompatibility potential and ability to withstand sterilization make it suitable for medical device prototypes and enclosures. The material's clarity in thin sections enables visualization of internal mechanisms.

Key Applications

  • Diagnostic equipment housings
  • Surgical instrument handles and grips
  • Medical device enclosures and covers
  • Laboratory equipment components

Performance Data

Withstands gamma sterilization up to 25 kGy and EtO cycles while maintaining 95% of mechanical properties, suitable for medical device validation.

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Polycarbonate enables durable manufacturing aids that survive production environments. The material's strength and chemical resistance allow fixtures and tools to withstand thousands of cycles with minimal wear.

Key Applications

  • Assembly fixtures and alignment jigs
  • Metal forming dies for low-volume production
  • Inspection gauges and go/no-go fixtures
  • Protective guards and machine covers

Performance Data

Survives 10,000+ production cycles with <0.5% dimensional change, enabling reliable tooling for runs up to 1,000 parts.

PC's strength-to-weight ratio and temperature resistance enable aerospace applications from cabin components to assembly tooling. The material meets requirements for non-structural interior parts.

Key Applications

  • Non-structural cabin components
  • Assembly and drilling fixtures
  • Protective covers for avionics
  • Environmental control system components

Performance Data

Heat deflection temperature of 143°C allows paint baking cycles at 120°C, while maintaining ±0.25 mm tolerances critical for aerospace assemblies.

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Polycarbonate production examples

FDM applications showcase

FDM applications showcase

Industrial FDM Applications

High-impact polycarbonate component

High-impact polycarbonate component

Automotive Component

Aerospace ducting assembly

Aerospace ducting assembly

Aerospace Application

Performance Dashboard

Technical performance for Polycarbonate

Polycarbonate delivers dependable strength and impact resistance for High-temperature automotive components and Aerospace interior panels and ducting, helping teams move from prototype to production with confidence.

Mechanical Properties

Tensile Strength, Yield (XZ Axis)

40 MPa

Tested to ASTM D638

Polycarbonate records Tensile Strength, Yield (XZ Axis) at 40 MPa, reinforcing its mechanical properties story.

Mechanical Properties

Tensile Strength, Yield (ZX Axis)

30 MPa

Tested to ASTM D638

Polycarbonate records Tensile Strength, Yield (ZX Axis) at 30 MPa, reinforcing its mechanical properties story.

Mechanical Properties

Tensile Strength, Ultimate (XZ Axis)

57 MPa

Tested to ASTM D638

Polycarbonate records Tensile Strength, Ultimate (XZ Axis) at 57 MPa, reinforcing its mechanical properties story.

Polycarbonate combines Exceptional impact resistance - superior to standard thermoplastics and High heat deflection temperature up to 143°C for demanding thermal environments to support High-temperature automotive components and Aerospace interior panels and ducting that demand production-ready durability.

Measurement
PolycarbonateBase
Standard
Tensile Strength, Yield (XZ Axis)40 MPaASTM D638
Tensile Strength, Yield (ZX Axis)30 MPaASTM D638
Tensile Strength, Ultimate (XZ Axis)57 MPaASTM D638
Tensile Strength, Ultimate (ZX Axis)42 MPaASTM D638
Tensile Modulus (XZ Axis)1944 MPaASTM D638
Tensile Modulus (ZX Axis)1958 MPaASTM D638
Tensile Elongation at Break (XZ Axis)4.8 %ASTM D638
Tensile Elongation at Break (ZX Axis)2.5 %ASTM D638
Tensile Elongation at Yield (XZ Axis)2.2 %ASTM D638
Tensile Elongation at Yield (ZX Axis)2.0 %ASTM D638
Flexural Strength (XZ Axis)89 MPaASTM D790
Flexural Strength (ZX Axis)68 MPaASTM D790
Flexural Modulus (XZ Axis)2006 MPaASTM D790
Flexural Modulus (ZX Axis)1800 MPaASTM D790
Flexural Strain at Break (XZ Axis)No breakASTM D790
Flexural Strain at Break (ZX Axis)4 %ASTM D790
IZOD Impact, Notched (XZ Axis)73 J/mASTM D256
IZOD Impact, Notched (ZX Axis)28 J/mASTM D256
IZOD Impact, Unnotched (XZ Axis)877 J/mASTM D256
IZOD Impact, Unnotched (ZX Axis)187 J/mASTM D256
Compressive Strength, Yield (XZ Axis)69 MPaASTM D695
Compressive Strength, Yield (ZX Axis)64 MPaASTM D695
Compressive Strength, Ultimate (XZ Axis)193 MPaASTM D695
Compressive Strength, Ultimate (ZX Axis)65 MPaASTM D695
Compressive Modulus (XZ Axis)7564 MPaASTM D695
Compressive Modulus (ZX Axis)1565 MPaASTM D695
Mechanical Performance

Mechanical Properties

Polycarbonate delivers dependable strength and impact resistance for High-temperature automotive components and Aerospace interior panels and ducting, helping teams move from prototype to production with confidence.

Polycarbonate delivers exceptional mechanical performance with excellent strength characteristics, effectively handling demanding load conditions. Its balanced mechanical profile allows it to maintain structural integrity while preventing brittleness in critical applications.

These qualities make it well-suited for High-temperature automotive components, Aerospace interior panels and ducting, and Medical device enclosures and housings, providing long-term durability in demanding environments. Polycarbonate maintains dimensional stability over time, ensuring consistent performance across temperature and stress variations.

This makes it a reliable choice for applications requiring precise geometries and tight tolerances across Aerospace, Automotive, and Medical Device Manufacturing. Its versatility and durability allow it to perform consistently across a wide range of mechanical applications, ensuring parts maintain their integrity under repetitive stress and environmental conditions.

Polycarbonate combines Exceptional impact resistance - superior to standard thermoplastics and High heat deflection temperature up to 143°C for demanding thermal environments to support High-temperature automotive components and Aerospace interior panels and ducting that demand production-ready durability.

Material Makeup

Physical Properties

Polycarbonate offers consistent density and surface quality so critical features hold tolerances and downstream finishing remains predictable.

Polycarbonate exhibits optimal density characteristics that contributes to lightweight yet durable parts. Its low moisture absorption ensures dimensional stability in varying environmental conditions.

These physical properties enable consistent part quality and predictable performance across High-temperature automotive components, Aerospace interior panels and ducting, and Medical device enclosures and housings. The material's inherent characteristics minimize warpage and maintain tight tolerances throughout the part lifecycle.

For Aerospace, Automotive, and Medical Device Manufacturing, these physical attributes translate to reliable production outcomes with minimal post-processing requirements, ensuring parts meet specifications straight from the build platform.

Polycarbonate keeps part quality consistent shot-to-shot, simplifying downstream finishing.

Heat Performance

Thermal Properties

Polycarbonate maintains dimensional stability through temperature swings, making it a reliable option for Aerospace and Automotive programs that see repeated thermal cycling.

Polycarbonate demonstrates excellent thermal stability with a heat deflection temperature of 138 °C, enabling it to maintain dimensional accuracy in elevated temperature environments. This thermal performance ensures parts retain their shape and mechanical properties even under thermal stress.

The material's thermal characteristics make it ideal for High-temperature automotive components, Aerospace interior panels and ducting, and Medical device enclosures and housings that experience temperature fluctuations. Its ability to withstand thermal cycling without degradation ensures long-term reliability in Aerospace, Automotive, and Medical Device Manufacturing.

With broad temperature tolerance, Polycarbonate provides engineers with confidence when designing parts for thermally demanding applications, from under-hood automotive components to industrial equipment exposed to heat sources.

Polycarbonate maintains geometry with a Heat Deflection Temperature @ 66 psi of 138 °C, protecting dimensional integrity during heat cycling.

Functional Performance

Electrical Properties

Polycarbonate offers controlled resistivity and dielectric performance for electrical housings, connectors, and functional prototypes.

Polycarbonate is designed for electrical housings and insulating features that require controlled electrical behavior. Its measured resistivity of 6.0E13 - 2.0E14 ohm-cm and dielectric strength of 80 - 360 V/mil support reliable performance in electrical assemblies.

A dissipation factor of 0.0005 - 0.0006 helps evaluate dielectric losses in signal-sensitive or high-frequency use cases. These electrical characteristics support High-temperature automotive components, Aerospace interior panels and ducting, and Medical device enclosures and housings where consistent insulation and repeatable part behavior are critical.

For Aerospace, Automotive, and Medical Device Manufacturing, Polycarbonate delivers dependable electrical performance for both functional prototypes and production parts used in integrated electrical systems.

Polycarbonate posts 6.0E13 - 2.0E14 ohm-cm Volume Resistivity, giving enclosures dependable insulating performance.

Compatibility Data

Chemical Properties

Polycarbonate offers tested chemical resistance across acids, bases, solvents, and hydrocarbons to ensure reliable performance in harsh environments.

Polycarbonate includes compatibility results for 10 chemical conditions, with 2 rated excellent and 4 rated good.

The profile supports use in High-temperature automotive components, Aerospace interior panels and ducting, and Medical device enclosures and housings when fluid exposure stays within the rated compatible categories and concentrations.

The dataset spans acids, bases, solvents, and hydrocarbons so teams can map likely pass/fail behavior early for High-temperature automotive components, Aerospace interior panels and ducting, and Medical device enclosures and housings and avoid unsuitable fluid-contact conditions.

For Aerospace, Automotive, and Medical Device Manufacturing, chemical ratings should be treated as screening guidance and confirmed with application-specific testing before production release.

Polycarbonate has 10 documented chemical exposures with 6 rated good or excellent for fluid-contact design screening.

Resources

Datasheets and design resources

Equip your team with certification packs, design guides, and spec sheets tailored to Polycarbonate.

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Access the most recent datasheet and supporting documentation maintained by our engineering team.

Resources

Material DatasheetMechanical Properties Overview

Design guidelines

Explore printable geometry recommendations, wall thickness tips, and finishing playbooks for FDM.

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Compliance certificates

Keep your quality packet current with pre-approved certifications.

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Advanced Manufacturing

Built with Precision FDM Technology

Polycarbonate is manufactured using Fused Deposition Modeling (FDM) technology, offering reliable performance for functional prototypes and end-use parts.

FDM Manufacturing Lab

Polycarbonate runs on industrial FDM platforms with heated chambers, hardened extrusion paths, and qualified material profiles to guarantee consistent layer adhesion and mechanical integrity.

Process Parameters

Layer Height
0.25 mm
Tolerance
±0.25 mm or ±0.3%, whichever is greater
  • Build Volume: 914 × 610 × 914 mm. Large production capacity enables efficient manufacturing of multiple parts or assemblies.
  • Quality Control. In-process monitoring and batch traceability ensure consistent part quality and material properties.

Finishing Options

Support removalSurface finishingVapor polishingPaintingThreading
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Frequently Asked Questions

Frequently asked questions about Polycarbonate

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Polycarbonate is known for its exceptional impact resistance - superior to standard thermoplastics, high heat deflection temperature up to 143°c for demanding thermal environments, outstanding dimensional stability with minimal thermal expansion, making it suitable for aerospace and automotive applications.
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