Polycarbonate (PC)

International Equivalent / Representative Grades

Design Purpose

Polycarbonate for additive manufacturing was developed to bridge the gap between basic desktop polymers and truly engineering-grade materials. Its design purpose is to deliver high impact strength, heat resistance, and dimensional accuracy in printed parts that must perform like injection-molded components. In industrial 3D printing services, PC allows engineers to validate mechanical performance early in the design cycle, create functional fixtures and jigs, and even run low-volume production with confidence. The material formulation prioritizes toughness, stiffness, and thermal stability, while maintaining printability when processed using controlled environments and optimized profiles. This balance makes PC ideal for enclosures, brackets, tooling inserts, and safety-critical covers where failure risk must be minimized.

Chemical Composition

Physical Properties

Mechanical Properties

Key Material Characteristics

• High impact resistance makes PC ideal for functional prototypes, fixtures, and protective covers subjected to dynamic loads.

• The elevated glass transition temperature enables PC 3D printed parts to maintain their stiffness and strength at higher service temperatures.

• Good dimensional stability and low creep support long-term accuracy in brackets, housings, and alignment features.

• Excellent balance of stiffness and toughness enables robust snap-fit designs and living hinges when properly engineered.

• Relative transparency in base resin allows translucent or light-diffusing parts when surface finish and wall thickness are optimized.

• Chemical resistance to various oils, greases, and detergents makes it suitable for industrial and automotive environments.

• Good fatigue resistance supports repeated mechanical cycling in hinges, clips, and functional mechanisms.

• Compatibility with specialty plastics and blends enables tailoring for flame retardancy, increased stiffness, or enhanced processability.

• Capable of achieving fine details and smooth surfaces using optimized plastic 3D printing parameters and enclosed printers.

• Reliable performance for both prototypes and low-volume production, reducing the gap between development and mass manufacturing.

Processability in Different Manufacturing Methods

• Fused filament 3D printing with PC: Requires elevated nozzle and bed temperatures plus an enclosed build chamber to minimize warpage and layer separation.

• Industrial plastic 3D printing services allow fine-tuned print profiles, controlled cooling, and high infill densities for maximum mechanical performance.

• PC blends with ABS or other thermoplastics improve ease of printing while retaining much of PC’s toughness.

• Dimensional tolerances can be tightly controlled when process parameters are stable, enabling precise fits in multi-part assemblies.

• Drilling, tapping, and machining of printed PC are feasible, especially when using sharp tools and moderate cutting speeds.

• Thermoforming or localized heat bending is possible due to PC’s high Tg, allowing post-print shape adjustments.

• Bonding with compatible adhesives and solvent-based systems enables joining of PC components to other engineering plastics or metal inserts.

• Overmolding or insert integration can be simulated by printing PC around pre-positioned metal or composite elements.

• When combined with carbon-fiber-reinforced filaments, PC-based composites provide increased stiffness and reduced thermal expansion, making them ideal for precision parts.

• Good layer adhesion can be achieved when moisture content is controlled and printing parameters are optimized for the chosen PC grade.

Suitable Post-Processing Options

• Support removal and careful sanding yield smooth surfaces, especially when combined with appropriately fine layer heights during printing.

• Wet sanding followed by polishing can significantly improve transparency for light guides, lenses, or inspection windows.

• Painting with compatible coatings allows color matching and surface texturing for enclosures and prototype assemblies.

• Vapor polishing or controlled solvent exposure can locally enhance surface clarity, provided it is carefully managed to avoid stress cracking.

• Heat treatment below the glass transition temperature (Tg) can relieve residual stresses, thereby reducing the risk of warpage or cracking in demanding assemblies.

• Mechanical finishing, such as bead blasting, produces uniform matte textures for ergonomic grips and industrial housings.

• Insertion of threaded metal inserts after printing provides durable fastening points in load-bearing joints.

• Laser marking can add permanent part identification, orientation marks, or quality tracking codes without significant structural degradation.

• Integration into assemblies using metal or superalloy components is feasible when both stiffness and electrical insulation are required simultaneously.

Common Industries and Applications

• Aerospace and aviation: functional brackets, cable guides, and protective covers supporting aerospace systems.

• Automotive: interior components, sensor housings, and jigs for assembly lines within the automotive industry.

• Energy and power generation: enclosures, test fixtures, and sensor mounts in power generation and energy applications.

• Industrial automation: functional machine guards, end-of-arm tooling, and positioning fixtures.

• Electronics and instrumentation: rugged cases, connector housings, and mounting frames for sensitive devices.

• Medical-related equipment: non-contact fixtures and housings in pharmaceutical and food processing environments.

When to Choose This Material

• When parts must withstand elevated temperatures, where PLA, PETG, or basic standard resins would soften or deform.

• When high impact resistance and durability are essential, such as for protective housings, tool handles, or safety covers.

• When you require functional prototypes that closely simulate the behavior of injection-molded engineering plastics.

• When designing snap-fits, clips, or hinges that must endure assembly and repeated use without cracking.

• When dimensional stability and accurate fit are critical across a wide range of service temperatures.

• When industrial fixtures, jigs, or gauges must resist oils, lubricants, and cleaning chemicals.

• When seeking a robust intermediate step between easy-print materials and ultra-high-end high-performance polymers like PEEK.

• When components are exposed to repetitive mechanical loads and fatigue, long-term reliability is a key requirement.

• When leveraging Neway’s plastic 3D printing capability to transition quickly from design to functional testing and limited production.