Aerospace
Cabin Prototypes & Aircraft Tooling
Cabin and duct prototypes, avionics covers and fixtures, with curved trim 631 mm long printed in one piece.
Fused Deposition Modeling Polycarbonate For Strong, Heat-Resistant Engineering Parts
Large Build Volume
Up to 914 × 610 × 914 mm
FDM material
Polycarbonate overview
Stratasys Polycarbonate (PC) is a strong, tough thermoplastic for Fused Deposition Modeling (FDM) parts that need to take knocks and stay rigid in the heat. It is stronger and more heat resistant than ABS and ASA, keeps its toughness under repeated stress instead of turning brittle, and holds its shape in hot vehicle interiors and near equipment that runs warm. Large parts print in one piece with no tooling. Use it for functional prototypes, jigs, fixtures and forming dies, aircraft cabin prototypes, dashboard parts, HVAC ducts and device housings.
How Polycarbonate is manufactured
Polycarbonate is manufactured using Fused Deposition Modeling (FDM) on Stratasys Fortus systems, which extrude the filament layer by layer inside a heated build chamber. The heated chamber gives strong layer adhesion and minimal warpage, critical for large structural parts, and the large build envelope produces big parts in one piece. Combined with its impact and heat resistance, FDM makes Polycarbonate suited to tooling, fixtures and functional housings.
- Build volume
- 914 × 610 × 914 mm
- Lead time
- 2-4 business days
- Layer height
- 0.25 mm
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Industry applications
Industry applications for Polycarbonate
Polycarbonate is the material of choice for functional prototypes and end-use parts that need durability and heat resistance together. It outperforms ABS and ASA on strength and heat resistance, and unlike brittle high-temperature materials, PC maintains toughness under repeated stress.
From rapid prototyping to production runs, teams rely on Polycarbonate to maintain tight tolerances while reducing assembly complexity through consolidated part designs. With no tooling, it also covers low-volume production where moulded PC is not cost-justified. Breakaway and soluble support materials allow complex geometries while keeping the clean surface finish required for functional testing and assembly validation.
With good electrical insulation and resistance to common cleaning and washer fluids, PC serves applications from automotive interiors and aircraft cabin prototypes to medical device housings, electronics enclosures, safety housings and manufacturing tooling.
Automotive
Interior Components & HVAC Parts
Dashboard, instrument cluster and HVAC parts that hold their shape up to 141 °C under load.
Industrial Tooling
Metal Forming Dies, Jigs & Fixtures
Fixtures, gauges and guards, and metal forming dies for runs of 500 to 1,000 units.
Medical & Healthcare
Diagnostic Housings & Lab Equipment
Diagnostic housings, lab components and test fixtures for device development.
Aerospace
Cabin Prototypes & Aircraft Tooling
Aerospace teams use Polycarbonate for cabin component and duct prototypes, avionics covers, and the assembly and drilling fixtures used to install them. Its strength-to-weight ratio and temperature resistance suit fit-check parts and line tooling alike, and Forge has printed curved polycarbonate cabin trim 631 mm long in one piece.
- Cabin prototypes and fit-check parts
- Assembly and drilling fixtures
- Avionics covers
Automotive
Interior Components & HVAC Parts
Automotive teams use Polycarbonate for dashboard components, instrument cluster housings, HVAC ducting and headlight housings. Its impact resistance and heat stability suit parts that need both structural integrity and aesthetic quality, holding their shape up to 141 °C under a 1.82 MPa load.
- Dashboard and instrument cluster parts
- HVAC ducting and ventilation
- Headlight housings and brackets
Industrial Tooling
Metal Forming Dies, Jigs & Fixtures
Manufacturing teams use Polycarbonate for assembly fixtures, inspection gauges and machine guards that take daily handling. Its strength and toughness let manufacturing aids survive production environments, and with a compressive yield strength of 106 MPa, it carries clamping and forming loads. PC metal forming dies handle production runs of 500 to 1,000 units.
- Assembly fixtures and alignment jigs
- Metal forming dies
- Inspection gauges and machine guards
Medical & Healthcare
Diagnostic Housings & Lab Equipment
Medical device teams use Polycarbonate for diagnostic equipment housings, device enclosures, instrument handle prototypes and the test fixtures used in verification builds. Housings print in the same polymer as the moulded PC parts they prototype, so form, fit and function are proven before the mould is finalised. For patient-contact parts, choose the ULTEM 1010 certified grade or USP Class VI ClearVue, both tested for biocompatibility.
- Diagnostic equipment housings
- Device enclosures and covers
- Lab equipment components
Performance data
Technical performance for Polycarbonate
Values from the Stratasys PC datasheet, tested to the standard listed with each property. Dielectric strength comes from Stratasys's earlier PC sheet.
Mechanical performance
Mechanical properties
Polycarbonate delivers dependable strength and impact resistance for heat-exposed automotive components, aerospace tooling and cabin prototypes, helping teams move from prototype to production with confidence. Its balanced mechanical profile handles demanding load conditions without turning brittle in critical parts.
FDM parts are strongest along the build plane. XZ values describe parts printed on edge and ZX values parts printed upright, so orient the main load path along the layers. Polycarbonate maintains dimensional stability and integrity under repetitive stress, for parts that need precise geometries.
PropertyValue
- Tensile Strength, Yield (XZ)ASTM D638
- 93.9 MPa
- Tensile Strength, Yield (ZX)ASTM D638
- 53.1 MPa
- Tensile Strength, Break (XZ)ASTM D638
- 54.1 MPa
- Tensile Strength, Break (ZX)ASTM D638
- 52.6 MPa
- Tensile Modulus (XZ)ASTM D638
- 2940 MPa
- Tensile Modulus (ZX)ASTM D638
- 2880 MPa
- Elongation at Yield (XZ)ASTM D638
- 4.8 %
- Elongation at Yield (ZX)ASTM D638
- 1.9 %
- Elongation at Break (XZ)ASTM D638
- 12 %
- Elongation at Break (ZX)ASTM D638
- 1.9 %
- Flexural Strength at 5% Strain (XZ)ASTM D790, Procedure A
- 144 MPa
- Flexural Strength at Break (XZ)ASTM D790, Procedure A
- No break
- Flexural Strength at Break (ZX)ASTM D790, Procedure A
- 85.3 MPa
- Flexural Modulus (XZ)ASTM D790, Procedure A
- 3430 MPa
- Flexural Modulus (ZX)ASTM D790, Procedure A
- 2800 MPa
- Flexural Strain at Break (XZ)ASTM D790, Procedure A
- No break
- Flexural Strain at Break (ZX)ASTM D790, Procedure A
- 3.1 %
- Compressive Yield Strength (XZ)ASTM D695
- 106 MPa
- Compressive Yield Strength (ZX)ASTM D695
- 106 MPa
- Compressive Modulus (XZ)ASTM D695
- 2600 MPa
- Compressive Modulus (ZX)ASTM D695
- 2560 MPa
- Izod Impact, Notched (XZ)ASTM D256
- 45.8 J/m
- Izod Impact, Notched (ZX)ASTM D256
- 30.7 J/m
- Izod Impact, Unnotched (XZ)ASTM D4812
- 1930 J/m
- Izod Impact, Unnotched (ZX)ASTM D4812
- 143 J/m
Material makeup
Physical properties
Consistent density and surface quality keep critical features in tolerance and downstream finishing predictable. Parts meet specifications once supports are removed, and assemblies fit without secondary rework.
PropertyValue
- Specific Gravity (23 °C, moulded plaque)ASTM D792
- 1.20
Heat performance
Thermal properties
Polycarbonate is amorphous, so it has no melting point; it softens around its glass transition, and its heat deflection temperatures sit close to it. Because it keeps its stiffness almost up to that point, parts stay dimensionally stable through temperature swings, from automotive interiors to industrial equipment exposed to heat sources.
Thermal expansion is listed by direction and temperature range. Use the range that matches the service temperature when sizing clearances and fits.
PropertyValue
- HDT @ 0.45 MPa / 66 psi (XY / XZ)ASTM D648, Method B
- 144.0 / 144.3 °C
- HDT @ 1.82 MPa / 264 psi (XY / XZ)ASTM D648, Method B
- 140.7 / 141.1 °C
- Glass Transition Temperature (Tg, inflection point, moulded plaque)ASTM D7426
- 142.5 °C
- Coefficient of Thermal Expansion (XZ, −50 to 120 °C)ASTM E831
- 49.2 ×10⁻⁶/K
- Coefficient of Thermal Expansion (XY, −50 to 30 °C)ASTM E831
- 51.6 ×10⁻⁶/K
- Coefficient of Thermal Expansion (XY, 30 to 75 °C)ASTM E831
- 35.8 ×10⁻⁶/K
- Coefficient of Thermal Expansion (XY, 75 to 130 °C)ASTM E831
- 11.5 ×10⁻⁶/K
- Thermal Conductivity (0 to 90 °C, moulded plaque)ASTM E1952
- 0.280–0.290 W/m·K
- Thermal Diffusivity (0 to 90 °C, moulded plaque)ASTM E1952
- 0.146–0.189 mm²/s
Functional performance
Electrical properties
Controlled resistivity and dielectric performance suit electrical housings, connectors, insulating features and functional prototypes, and give enclosures in integrated electrical systems dependable insulation.
Dielectric constant is given at 1 kHz and 2 MHz and dissipation factor at 2 MHz, each in two build directions; the dissipation factor helps evaluate dielectric losses in signal-sensitive or high-frequency use cases.
PropertyValue
- Volume Resistivity (moulded plaque)ASTM D257
- > 6.78×10¹⁴ Ω·cm
- Dielectric Constant, 1 kHz (XY / XZ)ASTM D150
- 2.66 / 2.84
- Dielectric Constant, 2 MHz (XY / XZ)ASTM D150
- 2.53 / 2.69
- Dissipation Factor, 2 MHz (XY / XZ)ASTM D150
- 0.003 / 0.008
- Dielectric StrengthASTM D149, Method A
- 80–360 V/mil
Compatibility data
Chemical properties
Stratasys rates PC good against alcohol, windshield washer fluid, deionized water and weak acids and bases. Oils, greases, fuels, brake fluid, coolant, esters and strong bases are rated limited, meaning short-term exposure will likely degrade the part. Ketones, halogenated solvents, phenols, strong acids and silicone greases are rated poor and will likely attack and aggressively degrade it, and PC is susceptible to stress cracking with certain solvents.
Stratasys ratings are relative and are screening guidance; confirm them with application-specific testing before production release.
ChemicalStratasys rating
- Alcohol / ethanol
- Good
- Windshield washer fluid
- Good
- Deionized water
- Good
- Weak acids (pH 3-6)
- Good
- Weak bases (pH 8-10)
- Good
- Aliphatic hydrocarbons (e.g. propane, butane)
- Limited
- Aromatic hydrocarbons (e.g. benzene)
- Limited
- Esters
- Limited
- Petroleum fuels
- Limited
- Motor oil
- Limited
- Transmission fluid
- Limited
- Petroleum greases
- Limited
- Brake fluid
- Limited
- Antifreeze / engine coolant
- Limited
- Strong bases (pH > 10)
- Limited
- Strong acids (pH < 3)
- Poor
- Ketones (e.g. MEK, acetone)
- Poor
- Halogenated hydrocarbons (e.g. CFCs)
- Poor
- Phenols
- Poor
- Silicone greases and oils
- Poor
Compliance
Compliance profile
Stratasys PC holds a UL Blue Card listing at UL 94 HB for horizontal and vertical builds. Aircraft cabin parts that must meet FAR 25.853 call for ULTEM 9085 or Antero 800NA, which carry that data.
Stratasys publishes no biocompatibility, food-contact or sterilization statement for this grade.
StandardStatus
- UL 94 flammabilityUL Blue Card E345258: HB at 0.30–0.66 mm minimum thickness, horizontal and vertical builds
- HB
Related materials
Compare Polycarbonate with similar materials
Resources
Datasheets and design resources
Datasheets, design guidance and supplier documentation for Polycarbonate.
Download center
Access the most recent datasheet and supporting documentation maintained by our engineering team.
Polycarbonate datasheetDesign guidelines
Explore printable geometry recommendations, wall thickness tips, and finishing playbooks for FDM.
View FDM design guide
Advanced Manufacturing
Built with Precision FDM Technology
Polycarbonate runs on industrial FDM platforms with qualified material profiles, offering reliable performance for functional prototypes and end-use parts and consistent mechanical integrity across every build.
- Tolerance
- ±0.25 mm or ±0.3%, whichever is greater
- Production capacity
- Multiple parts or assemblies built in each job
- Quality control
- In-process monitoring and batch traceability for consistent part quality and material properties
- Colours & finishes
- White or black; support removal, surface finishing, painting and threading
Frequently Asked Questions
Frequently asked questions about Polycarbonate
Can't find the answer you're looking for? Reach out to our customer support team.
- FDM Polycarbonate combines high impact resistance with a heat deflection temperature of 144 °C at 0.45 MPa, good dimensional stability for precise as-printed parts and good electrical insulation, making it suitable for aerospace and automotive applications.
- In FDM additive manufacturing, Polycarbonate is extruded layer by layer in a heated build chamber and used for heat-exposed automotive components, aerospace cabin prototypes and manufacturing tooling, because of its strength, heat resistance and dimensional accuracy.
- Polycarbonate is used across aerospace, automotive, medical device manufacturing, electronics, industrial equipment and consumer products for cabin prototypes and fixtures, dashboard and HVAC parts, device enclosures and housings, electronic equipment cases, jigs, fixtures and metal forming dies, and safety housings.
- Polycarbonate outperforms ABS and ASA on strength and heat resistance, keeps its toughness under repeated stress, deflects only at 144 °C under a 0.45 MPa load, insulates well electrically and works with both breakaway and soluble support materials, so it suits functional prototypes and end-use production parts alike.
- Polycarbonate needs support structures for overhangs and complex geometries, and it costs more than standard thermoplastics such as ABS. Stratasys rates ketones, halogenated solvents and strong acids poor and oils and fuels limited, and PC is susceptible to stress cracking with certain solvents; for parts wetted by fuel or oil, choose Nylon PA12. After 1,000 hours of accelerated UV ageing its upright strength at break fell by 29.2%, so ASA is the better choice for outdoor parts.
- Stratasys PC is rated UL 94 HB, the horizontal-burn class, and Stratasys publishes no V-0 or FAR 25.853 data for it. For aircraft cabin parts that must meet FAR 25.853, choose ULTEM 9085 or Antero 800NA, which carry that data.
- No. FDM Polycarbonate prints opaque, in white, unlike clear moulded polycarbonate. For transparent parts, choose Accura ClearVue in SLA or CNC-machined polycarbonate.
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STEP, STL, OBJ, 3MF and IGES supported
- Manufacturing technologies
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- Engineering materials
- 50+
- Part quantities
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