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 (Triton PC) For Strong, Heat-Resistant Engineering Parts
Large Build Volume
Up to 914 × 610 × 914 mm
FDM material
Polycarbonate overview
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. Triton PC is made from SABIC LEXAN polycarbonate resin for Stratasys Fortus printers. It has a glass transition temperature of 160 °C and holds its shape to 138 °C under a 0.45 MPa load, for prototypes, housings and tooling in warm service.
Also available in Stratasys PC.
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
Each value is tested to the standard listed with it. Compare the other grade or another material side by side.
Mechanical performance
Mechanical properties
Triton PC delivers the strength and stiffness of polycarbonate for functional prototypes, housings and tooling.
Triton PC values come from flat (XY) samples printed on a Fortus 400mc at 0.33 mm layers and tested to ISO standards, so they are not directly comparable with the ASTM values for Stratasys PC, which are measured on edge (XZ) and upright (ZX) on a Fortus 900.
PropertyTriton PC
- Tensile Strength, Break (XY)ISO 527
- 49.5 MPa
- Tensile Modulus (XY)ISO 527
- 1950 MPa
- Elongation at Break (XY)ISO 527
- 3.7 %
- Flexural Strength (XY)ISO 178
- 78 MPa
- Flexural Modulus (XY)ISO 178
- 1910 MPa
Material makeup
Physical properties
Triton PC is specified by its density, measured to ISO 1183.
PropertyTriton PC
- DensityISO 1183
- 1.2 g/cm³
Heat performance
Thermal properties
Triton PC has no specific melting point; it softens gradually over a wide temperature range around its glass transition, measured by DSC. Heat deflection is measured at 0.45 MPa on flat samples to ISO 75.
PropertyTriton PC
- HDT @ 0.45 MPa / 66 psi (XY)ISO 75
- 138 °C
- Glass Transition Temperature (Tg)DSC
- 160 °C
Functional performance
Electrical properties
Surface resistance above 10¹³ Ω/sq makes Triton PC an electrical insulator for housings and insulating features.
PropertyTriton PC
- Surface ResistanceIEC 60093
- > 10¹³ Ω/sq
Compatibility data
Chemical properties
Triton PC has no chemical ratings of its own; the table shows the Stratasys PC ratings.
Chemical ratings are screening guidance; confirm them with application-specific testing before production release.
Supplier data for Stratasys PC
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
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.
Triton PC 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 in Stratasys PC testing, 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, insulates well electrically and works with both breakaway and soluble support materials, so it suits functional prototypes and end-use production parts alike. Stratasys PC deflects only at 144 °C under a 0.45 MPa load.
- Both are polycarbonate filaments for Stratasys Fortus systems, for tough prototypes, housings and tooling. Stratasys PC is tested on edge (XZ) and upright (ZX) to ASTM standards, has chemical ratings and is rated UL 94 HB. Triton PC is made from SABIC LEXAN polycarbonate resin; its values come from flat (XY) samples tested to ISO standards, so they are not directly comparable with the Stratasys ASTM values. The UL 94 HB rating and chemical ratings belong to Stratasys PC; Triton PC carries no flammability, food-contact or biocompatibility rating. Each grade's datasheet lists its full test data.
- Polycarbonate needs support structures for overhangs and complex geometries, and it costs more than standard thermoplastics such as ABS. Stratasys PC is rated poor against ketones, halogenated solvents and strong acids and limited against oils and fuels, 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, the upright strength at break of Stratasys PC 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 has no V-0 or FAR 25.853 rating; Triton PC carries no flame rating. 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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