Material Guide: Polycarbonate (PC)

Polycarbonate (often called Lexan) is the material used in bulletproof glass and riot shields. In FTC, it is the king of durability.

The Properties

• Impact Strength: Virtually unbreakable. You can hit it with a hammer.
• Flexibility: It bends before it breaks.
• Transparency: It looks cool and lets you see your electronics.

Machining PC Sheet

This is the most common use.

• Buy 1/8” or 1/4” sheets from McMaster-Carr.
• CNC Router: Cuts like butter.
• Laser Cutter: DO NOT LASER PC. It releases chlorine gas which destroys your machine and your lungs.
• Bending: You can “cold bend” thin PC, or use a heat gun to fold it into complex intake shapes.

3D Printing PC

Printing PC is hardcore.

• Nozzle Temp: 300°C+ (Requires all-metal hotend).
• Bed Temp: 110°C+.
• Chamber: Must be enclosed and hot (60°C).
• Result: The strongest printed parts possible, but difficult to achieve without warping.

Verdict

Use machined PC sheets for intake sides, belly pans, and impact shields. Only print PC if you have a high-end industrial printer.