PC (Polycarbonate) in Rapid Prototyping Services

At PuKong Prototype, we specialize in delivering high-quality rapid prototyping services to meet diverse industrial and commercial needs. Among the materials we offer, Polycarbonate (PC) stands out due to its exceptional mechanical properties, thermal stability, and versatility. This document provides a detailed analysis of PC’s characteristics in rapid prototyping, covering material performance, deformation tendencies, application scope, temperature resistance, chemical durability, dimensional accuracy, and surface finishing options.

1. Material Properties of Polycarbonate (PC)

PC is an engineering-grade thermoplastic renowned for its:

• High impact resistance (250-900 J/m, far superior to ABS or PLA)

• Excellent transparency (up to 90% light transmission, similar to glass)

• Good heat resistance (glass transition temperature ~147°C)

• Lightweight yet strong (density: 1.2-1.22 g/cm³)

• Electrical insulation properties

These properties make PC ideal for functional prototypes requiring durability and structural integrity.

2. Deformation During Processing

PC is prone to warping and internal stresses during rapid prototyping due to its high melting point (~265°C) and thermal expansion. Key factors influencing deformation:

• Cooling rate: Uneven cooling leads to warping (controlled via heated build chambers in SLS or MJF).

• Layer adhesion: Poor layer bonding in FDM can cause delamination (optimized via enclosed 3D printers).

• Support structures: Necessary for overhangs to prevent sagging.

Mitigation Strategies:

• Annealing (post-processing heat treatment reduces internal stresses).

• Optimized print parameters (slower cooling, higher bed temperatures).

3. Application Scope

PC is widely used in industries requiring high-performance prototypes, including:

• Automotive (headlight lenses, dash components)

• Aerospace (ducting, housings)

• Medical (surgical instruments, sterilization-compatible parts)

• Electronics (transparent casings, insulating components)

• Consumer Goods (impact-resistant housings, safety goggles)

4. Temperature Resistance

PC performs exceptionally under thermal stress:

• Continuous use temperature: -40°C to 120°C (short-term up to 135°C)

• Flame retardancy: UL94 V-0/V-2 rated (self-extinguishing)

• Thermal expansion coefficient: 65-70 × 10⁻⁶/°C (lower than ABS but higher than PEEK)

Limitation: Prolonged exposure to >120°C environments may cause gradual degradation.

5. Durability & Chemical Resistance

PC offers moderate resistance to environmental and chemical exposure:

• Weathering/UV Resistance: Poor (requires UV-stabilized coatings for outdoor use).

• Hydrolysis Resistance: Susceptible to moisture absorption (~0.3% by weight). Pre-drying is essential before processing.

• Chemical Resistance:

• Good resistance to oils, alcohols, dilute acids.

• Poor resistance to strong acids (e.g., sulfuric acid), bases (e.g., NaOH), and ketones (e.g., acetone).

Solution: Post-processing coatings (e.g., acrylic lacquers) enhance chemical stability.

6. Dimensional Accuracy & Tolerance

PC’s precision depends on the prototyping method:

Note: PC’s low shrinkage (~0.5-0.7%) makes it better than ABS for tight-tolerance parts.

7. Surface Finishing Options

To enhance aesthetics and functionality, PC prototypes can undergo:

• Polishing: For optical clarity (used in lenses).

• Painting/Coating: Improves UV/chemical resistance.

• Vapor Smoothing: Chemical treatment (e.g., acetone vapor) for FDM parts.

• Texturing: Laser engraving or bead blasting for grip enhancement.

Conclusion

PC is a top-tier material for rapid prototyping services when impact strength, transparency, and thermal stability are critical. While it requires careful processing to avoid warping, its durability and versatility make it indispensable in automotive, aerospace, medical, and electronics industries.

At PuKong Prototype, we leverage advanced SLA,SLS, CNC machining, and injection molding techniques to ensure your PC prototypes meet the highest standards. Contact us today to discuss your project requirements!