Can polycarbonate be injection molded?
Yes, polycarbonate can be successfully injection molded and is one of the most commonly processed engineering thermoplastics. PC requires specific processing conditions including high melt temperatures (typically 280-320°C), elevated injection pressures (10,000-20,000 PSI), and proper drying before molding. With the right equipment, mold design, and process parameters, polycarbonate produces exceptional parts with high impact strength, optical clarity, and dimensional stability.
How to inject polycarbonate?
Injecting polycarbonate requires careful attention to several critical parameters: First, PC resin must be dried to less than 0.02% moisture content (typically 4 hours at 120°C). Barrel temperatures should range from 280-320°C depending on the grade. Injection pressure typically ranges from 10,000-20,000 PSI with injection speeds adjusted to prevent jetting and stress marks. Mold temperatures between 80-120°C help achieve optimal surface finish and dimensional accuracy. Proper venting is essential to prevent gas burns, and gate design must minimize shear stress to maintain optical clarity.
What is the injection pressure for polycarbonate?
Polycarbonate typically requires injection pressures between 10,000-20,000 PSI, significantly higher than many other thermoplastics. The exact pressure depends on part geometry, wall thickness, flow length, and the specific PC grade being used. Glass-filled polycarbonate grades may require pressures at the higher end of this range. Proper pressure ensures complete cavity fill, minimizes internal stress, and maintains dimensional accuracy. Our mold flow analysis determines optimal injection pressure for your specific polycarbonate component.
Is there a clear polycarbonate?
Yes, clear polycarbonate is widely available and is one of PC's most valued properties. Optical-grade polycarbonate offers exceptional clarity rivaling glass while providing superior impact resistance. Clear PC is commonly used for applications requiring transparency—including automotive lighting, safety shields, display covers, and consumer product housings. Various clear PC grades are available with different flow characteristics, UV stability, and optical properties. We help you select the right clear polycarbonate formulation for your specific clarity, strength, and processing requirements.
What is PC in injection molding?
PC stands for polycarbonate, a high-performance engineering thermoplastic widely used in injection molding. Polycarbonate is prized for its exceptional impact strength (250-300 times greater than glass), excellent optical clarity, high heat resistance (continuous use up to 115-130°C), and good dimensional stability. PC is commonly molded into parts for automotive, electronics, medical devices, safety equipment, and consumer products. Its combination of toughness, clarity, and moldability makes polycarbonate an ideal choice for demanding applications requiring both structural integrity and aesthetic appeal.
How much do polycarbonate injection molded parts cost?
Polycarbonate part costs vary based on part size, complexity, volume, and tooling requirements. PC resin is more expensive than commodity plastics like polypropylene, but its superior properties often justify the cost. Our pricing model emphasizes transparency—we itemize tooling costs, material costs, cycle time, and volume economics so you understand exactly where value is created. Contact us for a detailed quote on your specific polycarbonate component.
What lead time should I expect for PC injection molded parts?
Lead times depend on project complexity and whether you need prototyping, tooling, or production runs. Rapid polycarbonate prototypes can typically be delivered within 1-2 weeks. Production tooling generally requires 6-10 weeks depending on mold complexity. Once tooling is qualified, production parts can be manufactured efficiently with lead times based on order volume. We work closely with you to establish realistic timelines and can often accelerate schedules for urgent projects.
Do you provide design assistance for polycarbonate parts?
Absolutely. Our engineering team provides comprehensive design support specifically tailored to polycarbonate injection molding. We review your designs for moldability, recommend wall thickness optimization, suggest gate locations to minimize stress, and implement features that leverage PC's unique properties. Our CAD design services include design for manufacturing (DFM) analysis, tolerance reviews, and iterative refinement to ensure your polycarbonate component is optimized for both performance and cost-effective production.