Robotics & Automation
Machine Guards & Safety Windows
Guards and safety windows that absorb more than 20 times the impact energy of acrylic.
CNC Machining Polycarbonate For Impact-Resistant Transparent Parts
CNC Machining
Tight Tolerances
CNC machining material
Polycarbonate (CNC) overview
Polycarbonate is a clear, tough plastic for CNC machined windows, guards and covers that have to survive knocks. It takes many times more impact than acrylic without breaking, weighs almost half as much as glass, and machined faces polish back to a clear finish. It stays tough in cold weather, and a hard coating keeps faces that are cleaned or handled every day clear. Use it for machine guards and safety windows, instrument covers, lenses and light pipes, and protective visors in medical, industrial, electronics and transportation equipment.
How Polycarbonate (CNC) is manufactured
Polycarbonate (CNC) parts are cut from extruded polycarbonate sheet, plate or rod by CNC machining, not built in layers. Multi-axis machining produces precise pockets, bores, threads and mounting features, with the clarity and toughness of the stock running through the whole part. Clear faces are polished after machining wherever optical clarity is needed.
- Machining envelope
- 1000 × 600 × 500 mm
- Lead time
- 5-7 business days
- Tolerance
- ±0.050 mm typical
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Industry applications
Industry applications for Polycarbonate (CNC)
Polycarbonate (CNC) combines high impact strength and toughness with excellent optical clarity and polishability, delivering stable performance across a wide temperature range for demanding applications. It is trusted for medical and industrial equipment programs that need tough, transparent parts where uptime matters.
From rapid prototyping to production runs, teams rely on Polycarbonate (CNC) to hold tight tolerances. Machining from stock needs no moulds or minimum order quantities.
Where a part has to protect people and still let them see, polycarbonate is the usual choice, from protective visors and shields to consumer electronics windows. Hard-coated faces add the abrasion resistance bare polycarbonate lacks, so windows and covers that are cleaned or handled every day stay clear.
Medical Devices
Transparent Instrument Covers & Panels
Clear covers and panels that resist isopropyl alcohol, hydrogen peroxide and dilute hypochlorite.
Industrial Design & Electronics
Transparent Enclosures & Light Pipes
Clear enclosures, light pipes and lenses, machined in polycarbonate once the design is fixed.
Automotive & Transportation
Lighting Lenses & Sensor Covers
Lenses and sensor covers that hold their shape to 132 °C under load.
Robotics & Automation
Machine Guards & Safety Windows
Automation and equipment builders use machined polycarbonate for machine guards, safety windows, inspection covers and impact shields that let operators watch the process while staying protected. At 3.2 mm, clear polycarbonate sheet absorbs more than 20 times the impact energy of acrylic and survives a falling-ball impact that breaks both acrylic and glass. Tapped mounting holes and machined slots fit each guard straight to the frame.
- Machine guards and impact shields
- Safety and inspection windows
- Clear covers for automation cells
Medical Devices
Transparent Instrument Covers & Panels
Medical device teams specify polycarbonate for transparent instrument covers, device windows and instrument panels that must stay clear and survive knocks on a cart or bench. It resists isopropyl alcohol, 30% hydrogen peroxide and 5% sodium hypochlorite, so covers and panels stand up to routine wipe-down with these cleaners. Some commercial bleach-, peroxide- and quaternary-based healthcare disinfectants attack it, so each device is matched to compatible cleaners.
- Transparent instrument covers
- Device windows
- Instrument panels
Industrial Design & Electronics
Transparent Enclosures & Light Pipes
Product teams use machined polycarbonate for transparent control enclosures, display windows, light pipes and lenses. A proven route is to iterate the look and fit in clear SLA resin, then move to CNC polycarbonate once the geometry stabilizes, for parts that are tougher and ready for the field. Clear sheet transmits 86% of light at 3 mm with under 1% haze, machined faces are polished to restore clarity, and a dielectric strength of 15 kV/mm makes it an insulating window or cover over electronics.
- Transparent control enclosures
- Light pipes and lenses
- Display windows
Automotive & Transportation
Lighting Lenses & Sensor Covers
Vehicle and transportation teams prototype lighting lenses, light diffusers, sensor covers and impact-resistant lighting components in machined polycarbonate and carry them into low-volume builds. It holds its shape to 132 °C under a 1.82 MPa load and stays ductile well below freezing, so lenses and covers keep their impact toughness in cold weather.
- Lighting lenses and diffusers
- Sensor covers
- Impact-resistant lighting components
Performance data
Technical performance for Polycarbonate (CNC)
Values from the Plaskolite TUFFAK GP polycarbonate sheet datasheet, tested to the standard listed with each property. Values TUFFAK GP does not publish come from Ensinger TECANAT natural rod, plate and tube, named with each property.
Mechanical performance
Mechanical properties
Polycarbonate (CNC) delivers dependable strength and impact resistance for transparent instrument covers, safety guards and machine windows. Its balanced mechanical profile handles demanding load conditions without turning brittle in critical parts.
Polycarbonate yields and then stretches a long way before it breaks, and unnotched samples do not break at all. Notched values are lower, so generous internal radii at corners, slots and holes keep the full toughness of the material in machined parts. Instrumented impact shows the energy a flat panel absorbs under a falling dart, the best guide for guards and windows.
PropertyValue
- Tensile Strength, UltimateASTM D638
- 65.5 MPa
- Tensile Strength, YieldASTM D638
- 62 MPa
- Tensile ModulusASTM D638
- 2340 MPa
- Elongation at BreakASTM D638
- 110 %
- Flexural StrengthASTM D790
- 93 MPa
- Flexural ModulusASTM D790
- 2380 MPa
- Compressive StrengthASTM D695
- 86 MPa
- Compressive ModulusASTM D695
- 2380 MPa
- Izod Impact Strength, Notched (3.2 mm)ASTM D256
- 960 J/m
- Izod Impact Strength, Unnotched (3.2 mm)ASTM D256
- No break
- Instrumented Impact, Total Energy (3.2 mm)ASTM D3763
- 64 J
- Shear Strength, UltimateASTM D732
- 69 MPa
- Shear Strength, YieldASTM D732
- 41 MPa
- Shear ModulusASTM D732
- 786 MPa
- Rockwell Hardness (M / R)ASTM D785
- M70 / R118
- Poisson's RatioASTM E132
- 0.38
Material makeup
Physical properties
Polycarbonate (CNC) offers consistent density and surface quality, so critical features hold tolerances and downstream finishing remains predictable. Low density makes parts lightweight yet durable, and low moisture absorption keeps them dimensionally stable in varying environmental conditions.
Light transmission and haze are measured on the polished surface of clear sheet as supplied. A machined face is translucent until it is polished, so specify which faces need optical clarity; the refractive index helps when designing lenses and light pipes.
PropertyValue
- Specific GravityASTM D792
- 1.2
- Light Transmission, Clear (3 mm)ASTM D1003
- 86 %
- Haze, Clear (3 mm)ASTM D1003
- < 1 %
- Refractive IndexASTM D542
- 1.586
- Water Absorption (24 h)ASTM D570
- 0.15 %
Heat performance
Thermal properties
Polycarbonate (CNC) stays tough far below freezing and holds its shape up to its heat-deflection limit, so guards and windows in medical and industrial equipment can sit near heat sources. Heat deflection shows the short-term limit under load. For long-term use, Plaskolite gives a lower continuous service limit for clear sheet than the UL 746B rating Ensinger publishes for its rod, plate and tube, so use the sheet figure for sheet-based guards and windows.
Polycarbonate expands far more than metal, so allow clearance where clear panels are fastened into metal frames. Ignition temperatures and the horizontal burn result describe how it behaves in a fire; its UL 94 rating is listed with compliance.
PropertyValue
- HDT @ 1.82 MPa (264 psi)ASTM D648
- 132 °C
- HDT @ 0.45 MPa (66 psi)ASTM D648
- 138 °C
- Glass Transition TemperatureISO 11357 (Ensinger, public-source value)
- 149 °C
- Continuous Service Temperature (sheet)Plaskolite TUFFAK fabrication guide
- 100 °C
- Long-Term Service TemperatureUL 746B (Ensinger TECANAT natural)
- 121 °C
- Intermittent Service TemperatureEnsinger TECANAT natural data
- 135 °C
- Brittleness TemperatureASTM D746
- -129 °C
- Coefficient of Linear Thermal ExpansionASTM D696
- 67.5 ×10⁻⁶/K
- Thermal ConductivityASTM C177
- 0.19 W/m·K
- Specific HeatASTM C351 (Ensinger TECANAT natural)
- 1.26 J/g·K
- Self-Ignition TemperatureASTM D1929
- 550 °C
- Flash-Ignition TemperatureASTM D1929
- 440 °C
- Horizontal Burn, Average ExtentASTM D635
- < 25 mm
Functional performance
Electrical properties
Polycarbonate (CNC) is an electrical insulator with high resistivity and good dielectric strength, for insulating covers, windows and functional prototypes in integrated electrical systems where a UL 94 HB rating is acceptable. Flame-rated enclosures need a V-0 grade.
The dielectric constant and the low dissipation factor help evaluate dielectric losses in signal-sensitive or high-frequency use. Arc resistance is reported for two electrode types, as Plaskolite tests it.
PropertyValue
- Volume ResistivityASTM D257
- 8.2×10¹⁶ Ω·cm
- Surface ResistivityIEC 60093
- > 10¹⁴ Ω
- Dielectric Strength (3.2 mm, in air)ASTM D149
- 15 kV/mm
- Dielectric Constant (60 Hz)ASTM D150
- 3.17
- Dielectric Constant (1 MHz)ASTM D150
- 2.96
- Dissipation Factor (60 Hz)ASTM D150
- 0.0009
- Arc Resistance (tungsten / stainless strip electrodes)ASTM D495
- 120 / 10 s
Compatibility data
Chemical properties
Plaskolite rates polycarbonate in a bent-strip test at 23 °C and up to 2% strain, so the ratings show which chemicals crack a stressed part. Dilute acids, isopropyl and ethyl alcohol, mineral oils, salt water and oxidizers such as hydrogen peroxide and dilute sodium hypochlorite are tolerated, while bases, ammonia and amines, ketones, and chlorinated and aromatic solvents attack it, and fuels only partially resist.
Highly stressed parts can crack within a minute in an aggressive solvent, and plasticized PVC in contact can stress-crack polycarbonate, so confirm cleaners and contact materials with application-specific testing before production release.
ChemicalRating
- Acetic acid (up to 10%)
- Good
- Citric acid
- Good
- Hydrochloric acid 20%
- Good
- Hydrochloric acid (concentrated)
- Poor
- Sulfuric acid 50%
- Good
- Sulfuric acid 70%
- Moderate
- Sulfuric acid (concentrated)
- Poor
- Nitric acid up to 10%
- Good
- Nitric acid 10–20%
- Moderate
- Nitric acid above 20%
- Poor
- Phosphoric acid (concentrated)
- Good
- Sodium hydroxide (caustic soda)
- Poor
- Potassium hydroxide
- Poor
- Ammonia and amines
- Poor
- Isopropyl alcohol
- Good
- Ethyl alcohol 96%
- Good
- Methanol
- Poor
- Ethylene glycol
- Good
- Acetone
- Poor
- Methyl ethyl ketone (MEK)
- Poor
- Methylene chloride
- Poor
- Toluene and xylene
- Poor
- Hexane and heptane
- Good
- Gasoline
- Moderate
- Diesel oil
- Moderate
- Hydraulic and lubricating oils (mineral)
- Good
- Benzene
- Poor
- Sodium chloride (saturated) and sea water
- Good
- Calcium chloride (saturated)
- Good
- Sodium carbonate (saturated)
- Good
- Hydrogen peroxide 30%
- Good
- Sodium hypochlorite 5%
- Good
- Ozone
- Good
- Chlorine gas (wet)
- Poor
Compliance
Compliance profile
Plaskolite lists TUFFAK GP sheet under UL file E87887, and its UL 94 rating depends on wall thickness, so read the rating with the thickness it was tested at. Ensinger cites ASTM D6098 as the shapes specification for its TECANAT natural rod, plate and tube.
The FDA statement covers the resin in Ensinger stock shapes rather than a named food-contact regulation, so food-contact parts are confirmed with Forge Labs before ordering. Neither grade carries biocompatibility data, and Ensinger does not define TECANAT for medical or dental implants.
StandardStatus
- UL 94 flammabilityPlaskolite UL file E87887 for TUFFAK GP sheet: HB at 1.5 mm (0.060 in); V-0 only at 10 mm (0.394 in). Not a flame-retardant grade at thin sections
- HB
- ASTM D6098 (S-PC0111)Extruded polycarbonate rod, plate and tube for machining, the shapes specification Ensinger cites for TECANAT natural (resin to ASTM D3935 PC0150B34840)
- Stock specification
- FDA (resin)Ensinger lists FDA compliance for the resin used in TECANAT natural stock shapes; no CFR section or food-contact scope is named. TUFFAK GP sheet carries no food-contact statement
- Ensinger statement
Related materials
Compare Polycarbonate (CNC) with similar materials
Resources
Datasheets and design resources
Datasheets, design guidance and supplier documentation for Polycarbonate (CNC).
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Polycarbonate (CNC) datasheetDesign guidelines
Tolerance, wall thickness and finishing guidance for machined parts.
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Advanced Manufacturing
Built with Precision CNC Machining Technology
Polycarbonate (CNC) is manufactured using advanced CNC machining technology, ensuring optimal material properties and dimensional accuracy. Edges are finished and machining stress is relieved where a part needs it, keeping clear parts free of crazing.
- Production capacity
- Large work envelope for machining multiple parts or assemblies efficiently
- Quality control
- In-process monitoring and batch traceability for consistent part quality and material properties
- Colours & finishes
- Clear stock; deburring, flame polishing, vapor polishing and hard coating
Frequently Asked Questions
Frequently asked questions about Polycarbonate (CNC)
Can't find the answer you're looking for? Reach out to our customer support team.
- Polycarbonate (CNC) is known for high impact strength and toughness, excellent optical clarity and polishability, and stable performance across a wide temperature range, which suits medical and industrial equipment applications. Clear TUFFAK GP sheet has an ultimate tensile strength of 65.5 MPa, transmits 86% of light at 3 mm, and holds its shape to 132 °C under a 1.82 MPa load.
- Polycarbonate (CNC) parts are machined from extruded polycarbonate sheet, plate or rod in a 1000 × 600 × 500 mm machining envelope, to a typical tolerance of ±0.050 mm, with a lead time of 5-7 business days. Machining heat builds internal stress, so parts are stress relieved where needed to prevent crazing, and deburring, flame polishing, vapor polishing and hard coating are available. For 3D printed polycarbonate parts, Forge Labs also offers FDM Polycarbonate.
- Polycarbonate (CNC) is used across medical, industrial equipment, consumer electronics and transportation for transparent instrument covers, safety guards and machine windows, transparent housings, light pipes and lenses, impact-resistant lighting components, and protective visors and shields.
- Polycarbonate (CNC) offers high impact strength (unnotched Izod samples do not break), optical clarity with under 1% haze in clear 3 mm sheet, almost half the weight of glass, low water absorption (0.15% in 24 hours) and a brittleness temperature of -129 °C (ASTM D746). It also supports hard coating for abrasion resistance.
- Polycarbonate (CNC) is susceptible to chemical attack by strong solvents such as acetone, MEK, methylene chloride, toluene and xylene, and by bases, ammonia and amines. It requires stress relieving to prevent crazing, its scratch resistance is lower without hard coating, and standard clear stock has limited weathering resistance. Machined faces are translucent until they are polished.
- Plaskolite rates TUFFAK GP sheet for continuous service up to 100 °C, and Ensinger rates its TECANAT natural rod, plate and tube at 121 °C long term (UL 746B) and 135 °C intermittently. Polycarbonate deflects at 132 °C under a 1.82 MPa load, has a glass transition of 149 °C and a brittleness temperature of -129 °C.
- TUFFAK GP sheet is rated UL 94 HB at 1.5 mm and V-0 at 10 mm under Plaskolite UL file E87887, so it is not a flame-retardant grade at thin walls. Ensinger lists FDA compliance for the resin used in its TECANAT natural stock, without naming a food-contact regulation, and TUFFAK GP sheet has no food-contact statement, so food-contact parts should be confirmed with Forge Labs before ordering.
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