Short answer: Choose acrylic for clarity (92% light transmission vs about 86 to 88% for polycarbonate), scratch resistance, stiffness, polished edges, laser-cut shapes, and lower cost: signs, displays, frames, shelves, and covers. Choose polycarbonate (Lexan, Makrolon, Tuffak) when impact is the main concern, such as machine guards and security glazing: in Plaskolite's instrumented impact test it absorbed 64 J vs 2.4 J for acrylic, roughly 27 times more. Polycarbonate scratches more easily, costs more, and chars rather than cutting cleanly under a CO2 laser.
Acrylic vs polycarbonate at a glance
| Acrylic (PMMA) | Polycarbonate (PC) | |
|---|---|---|
| Light transmission | 92% (Acrylite, Optix) | 86% (Tuffak GP, 3 mm); 88% (Acrylite's Cyrolon) |
| Impact (instrumented, 1/8 in.) | 2.4 J | 64 J; glass 0.7 J on the same test |
| Drop ball, 0.5 lb | Breaks at about 2.4 J | No break |
| Stiffness (flexural modulus) | About 475,000 to 490,000 psi | About 345,000 psi (2,380 MPa) |
| Surface hardness (Rockwell M) | M-93 to M-95 | M70; scratches easily unless hard-coated |
| Cold bending | Minimum radius about 180 to 200 × thickness | About 100 × thickness |
| Heat | Continuous service 160 to 180 °F (71 to 82 °C); softens 220 to 239 °F | Heat deflection 270 °F (132 °C); softens about 291 °F (144 °C) |
| UV and outdoor use | Naturally UV stable; stays clear for decades | Needs UV-protected grades; Plaskolite rates general-purpose Tuffak GP as limited weathering |
| Laser cutting | Cuts cleanly with glossy edges | Over about 1 mm, cuts poorly, discolors, may ignite; usually routed or sawn |
| Edge polishing | Flame, diamond, or buff polishes well | Hard to polish to a clear edge |
| Fire (UL 94) | HB; burns | HB under 10 mm; V-0 at 10 mm and thicker (Tuffak GP clear) |
| Gluing | Solvent bonds easily into clear joints | Harder to bond cleanly |
| Drilling | Can crack if drilled wrong | Very forgiving |
| Cost | Lower | Higher |
Values are typical figures from Acrylite, Optix, and Tuffak data sheets; exact numbers vary by grade and manufacturer.
Which is stronger, acrylic or polycarbonate?
For impact, polycarbonate wins by a wide margin. In Plaskolite's instrumented impact test on 1/8 in. (3.2 mm) samples, glass absorbed 0.7 J before breaking, acrylic 2.4 J, and Tuffak GP polycarbonate 64 J: roughly 27 times acrylic and 90 times glass. You'll often see “250 times glass and 30 times acrylic” in marketing; the acrylic ratio holds up, the glass figure depends on the test. That's why polycarbonate is used for riot shields, machine guards, safety glasses, and bullet-resistant laminates. See is acrylic bulletproof.
For stiffness, acrylic wins. Its flexural modulus is roughly 40% higher, so an acrylic shelf or sign flexes less than the same panel of polycarbonate. Acrylic is still several times more impact resistant than glass, and plenty strong for most everyday uses. More in how strong is acrylic.
Which scratches less?
Acrylic. Polycarbonate is a softer surface (Rockwell M70 vs about M94 for acrylic) and picks up fine scratches from wiping, dust, and handling. Hard-coated polycarbonate solves much of this, but the coating adds cost and can't be polished out. Acrylic scratches too, but light scratches can be buffed out. Does acrylic scratch easily?
Can polycarbonate be laser cut?
Not well with a CO2 laser, which is what cuts acrylic so cleanly. Acrylic vaporizes under the beam, leaving a glossy edge. Polycarbonate chars instead: the University of Illinois laser safety guidance lists polycarbonate over 1 mm as a do-not-cut material because it cuts very poorly, discolors, and may ignite. That's why polycarbonate parts are normally routed, sawn, or die cut. If your design depends on fine laser-cut detail, engraving, or a polished edge, acrylic is the material to use. Can you laser cut acrylic?
Which is better outdoors?
Acrylic handles sunlight with no special treatment: Acrylite warrants its clear cast sheet to lose no more than 3% of its light transmission in 30 years. Plain polycarbonate yellows and gets brittle in sun, so outdoor polycarbonate sheet comes with a UV-protective layer on one or both sides, and that side has to face the sun. For greenhouses, skylights, and patio covers in hail country, UV-protected polycarbonate is popular because of its toughness. For outdoor signs and windows where clarity matters, acrylic is a strong choice. See can acrylic be used outdoors.
Which should you choose?
Choose acrylic for
- Signs, displays, awards, and anything engraved or laser cut into a shape
- Picture frames, table covers, and cabinet inserts where clarity matters
- Shelves and display cases (stiffer, clearer, cleaner glued joints)
- Sneeze guards and counter shields
- Projects on a budget
Choose polycarbonate for
- Machine guards where parts or chips can fly
- Windows in high-risk spots: schools, gyms, vandal-prone areas
- Parts that flex, snap, or get dropped repeatedly
- Hot environments above acrylic's service temperature
- Places where a specific fire rating is required (check your local code for what applies)
Not sure which you need? Describe the project on make it in acrylic. If acrylic fits, we'll cut, polish, drill, or bend it for you, and you can see your price instantly in the instant quote.
Questions
Is Lexan the same as acrylic?
No. Lexan is a brand of polycarbonate, as are Makrolon and Tuffak. Plexiglas, Acrylite, Perspex, Lucite, and Optix are brands of acrylic. They look the same but are different plastics.
How can I tell acrylic and polycarbonate apart?
Check the film first. On a scrap, polycarbonate bends a long way without breaking and scratches more easily, while acrylic is stiffer and snaps if bent hard. Polycarbonate's edges also often look slightly bluish or gray.
Should a sneeze guard be acrylic or polycarbonate?
For most counters, acrylic: it's clearer, stays clear with cleaning, and costs less. Use polycarbonate if the shield will be hit or leaned on hard.
Which handles heat better?
Polycarbonate. Tuffak GP's heat deflection temperature is 270 °F (132 °C), against about 195 to 210 °F for acrylic, so polycarbonate suits light fixtures and hot enclosures where acrylic would soften.
Is polycarbonate heavier than acrylic?
Only slightly. Polycarbonate's density is about 1.20 g/cm³ vs 1.19 for acrylic; Plaskolite lists 1/8 in. sheet at 3.81 kg/m² for polycarbonate and 3.66 kg/m² for acrylic. Both are about half the weight of glass.
Sources
- Plaskolite: TUFFAK GP polycarbonate sheet data (with acrylic and glass comparison)
- Acrylite: Cell cast sheet (GP) physical properties
- Plaskolite: OPTIX acrylic sheet typical properties
- University of Illinois Division of Research Safety: Laser cutters, safe use
- Acrylite: Color number chart (Cyrolon polycarbonate transmission)