Acrylic transmits 92% of visible light and costs 25-35% less per sheet. Polycarbonate resists impact 250 times better than glass and handles temperatures up to 240°F. Those two facts answer the question for most buyers, but the right choice depends on your specific project. For more information, see the poly(methyl methacrylate) (Wikipedia).
We manufacture and sell both acrylic sheets and polycarbonate sheets at KASTLITE. Over the years, we've helped thousands of customers pick the right material for jobs ranging from picture framing to machine guards. This guide covers every property that matters, with verified numbers, so you can make the call with confidence. For more information, see the polycarbonate (Wikipedia).
What Is Acrylic?
Acrylic is the common name for polymethyl methacrylate (PMMA). You may also hear it called Plexiglass, Lucite, or Perspex, which are all brand names for the same base polymer. Acrylic was first produced commercially in the 1930s and quickly became the go-to glass alternative for applications that demand optical clarity without the weight or fragility of glass.
The material transmits 92% of visible light, which actually exceeds glass at 90%. It weighs roughly half as much as glass of the same size. Acrylic is naturally UV stable, with as little as 3% degradation after 10 years of outdoor exposure, according to data published by Evonik (the maker of ACRYLITE). That UV stability means acrylic holds its water-clear appearance for years without yellowing.
Acrylic cuts cleanly with standard woodworking tools, can be polished to restore scratches, and bonds well with solvent-based adhesives. It is about 17 times more impact-resistant than standard glass, which makes it a solid upgrade for windows, displays, and signage. But it is also more brittle than polycarbonate. A hard strike can crack an acrylic panel, and drilling without proper technique can cause it to chip or fracture at the hole.
Common applications for acrylic include retail displays, picture frames, aquarium panels, skylights, sneeze guards, signage, and light diffusers. Our 1/8" clear acrylic sheets and 1/4" clear acrylic sheets are our most popular sizes for these projects.
What Is Polycarbonate?
Polycarbonate (PC) is a thermoplastic polymer known primarily for extreme impact resistance. The most recognized brand names are Lexan (by SABIC) and Makrolon (by Covestro). Polycarbonate was developed in the late 1950s by GE and Bayer simultaneously, and it found early adoption in bulletproof glazing, aircraft canopies, and riot shields.
The material transmits 88% of visible light. It weighs about half as much as glass, almost identical to acrylic on a per-volume basis (specific gravity of 1.20 vs. 1.19 for acrylic). Polycarbonate can handle continuous service temperatures up to 240°F (115°C), compared to acrylic's limit of around 176°F (80°C). That higher heat tolerance matters for applications near lighting fixtures, industrial equipment, or outdoor enclosures in direct sun.
The headline feature is impact resistance. Polycarbonate is 250 times more impact-resistant than standard glass and about 30 times stronger than acrylic. You can hit a polycarbonate panel with a hammer and it will flex rather than shatter. That same hit would crack acrylic and destroy glass.
Polycarbonate does scratch more easily than acrylic, and unlike acrylic, scratches cannot be buffed out. It also costs 25-35% more per sheet for the same thickness. Without a UV-protective coating, polycarbonate will yellow over time from sun exposure. Most quality polycarbonate sheets ship with a UV-coated side, but you need to install it correctly (coated side facing the sun).
Common applications include safety glazing, machine guards, greenhouse panels, protective barriers, skylights in high-traffic areas, and any project where breakage is a safety concern. Browse our full polycarbonate sheet collection to see available thicknesses.
Acrylic vs Polycarbonate: Side-by-Side Comparison
This table summarizes the key differences between acrylic and polycarbonate sheets. All numbers are based on standard clear sheets at comparable thicknesses.
| Property | Acrylic (PMMA) | Polycarbonate (PC) |
|---|---|---|
| Light Transmission | 92% | 88% |
| Impact Resistance (vs. glass) | 17x stronger | 250x stronger |
| Impact Resistance (vs. acrylic) | Baseline | 30x stronger |
| Weight (vs. glass) | ~50% lighter | ~50% lighter |
| Specific Gravity | 1.19 g/cm³ | 1.20 g/cm³ |
| Max Continuous Service Temp | 176°F (80°C) | 240°F (115°C) |
| UV Resistance | Naturally UV stable (3% degradation over 10 years) | Needs UV coating to prevent yellowing |
| Scratch Resistance | Higher (can be polished to remove scratches) | Lower (scratches cannot be buffed out) |
| Flammability | Combustible (burns if ignited) | Self-extinguishing (UL94 V-2 rating standard, V-0 with FR additive) |
| Chemical Resistance | Good (damaged by acetone, solvents) | Better (resists most acids, oils, greases) |
| Machinability | Cuts cleanly, can crack during drilling | Harder to cut cleanly, won't crack when drilled |
| Cold Forming | Rigid, needs heat to bend | Flexible, can be cold-formed without cracking |
| Relative Cost | Lower (25-35% less than polycarbonate) | Higher |
When to Choose Acrylic
Acrylic is the better choice whenever optical clarity, cost, and appearance matter more than impact strength. Here are the situations where acrylic outperforms polycarbonate.
Retail Displays and Point-of-Purchase Stands
The 92% light transmission gives products behind acrylic a crisp, undistorted look. Polycarbonate's slight tint and lower clarity can make merchandise appear dull by comparison. If the panel is inside a store where nobody is going to hit it with a baseball bat, acrylic wins.
Picture Frames and Museum Cases
Acrylic's UV stability protects artwork from fading without the need for special coatings. Its scratch resistance keeps the surface clear with normal cleaning. Museum-grade acrylic (like ACRYLITE OP-3) blocks 98% of UV radiation, which is why it replaced glass in many galleries.
Signage and Lettering
Acrylic cuts cleaner than polycarbonate on laser cutters and CNC routers, producing polished edges that need no post-processing. Colored acrylic sheets hold vibrant, consistent color. Our colored acrylic sheet packs are popular with sign makers for exactly this reason.
Aquariums and Fish Tanks
Large aquariums use acrylic panels because the material can be solvent-welded into seamless joints that are as strong as the sheet itself. Glass cannot do this. The higher light transmission also makes aquarium contents appear brighter and more vivid.
Skylights and Roof Panels (Low-Traffic Areas)
For skylights that are not at risk of hail damage or foot traffic, acrylic provides better clarity and UV performance at a lower cost. Acrylic dome skylights have been standard in residential construction for decades because the material holds up well in sunlight without yellowing.
Light Diffusers and Lens Covers
Acrylic is the standard material for fluorescent light covers, LED panel diffusers, and decorative light fixtures. Its clarity, light weight, and ease of thermoforming make it ideal for these applications. KASTLITE started in this business, and we still manufacture a wide range of plastic light diffuser panels.
When to Choose Polycarbonate
Polycarbonate is the right material when the panel might take a hit, face extreme temperatures, or sit in an environment where breakage creates a safety hazard. Here are the projects where polycarbonate clearly wins.
Safety Glazing and Protective Barriers
Machine guards, protective shields, and security windows need a material that absorbs impact without shattering. Polycarbonate's 250x-glass impact rating makes it the only real choice. OSHA guidelines often require polycarbonate in industrial settings for this reason.
Greenhouses and Agricultural Enclosures
Multi-wall polycarbonate sheets offer better insulation (higher R-value) than single-layer acrylic or glass while still transmitting enough light for plant growth. The material can take hail strikes that would shatter acrylic. Twin-wall polycarbonate panels provide an R-value of about 1.42 at 6mm thickness, compared to approximately 0.83 for single-pane glass.
Bullet-Resistant and Security Glazing
Polycarbonate is the base material in bullet-resistant "glass" systems. Layered polycarbonate (sometimes combined with acrylic outer layers for scratch resistance) can stop handgun rounds. Banks, government buildings, and convenience stores depend on this material.
Outdoor Enclosures in Extreme Climates
Polycarbonate handles temperatures from -40°F to 240°F without becoming brittle or warping. In regions with wide temperature swings, or where panels sit near heat sources, polycarbonate outperforms acrylic. Acrylic can warp or soften at sustained temperatures above 176°F.
High-Traffic Areas and Vandal-Prone Installations
Bus shelters, transit stations, and outdoor kiosks use polycarbonate because it resists deliberate damage. A punch or kick that would shatter an acrylic panel will bounce off polycarbonate. The material flexes under load and returns to shape.
Roofing and Canopy Panels in Hail Zones
If you live anywhere that gets hail, polycarbonate is the safer bet for patio covers, carports, and walkway canopies. A 1-inch hailstone traveling at terminal velocity will crack most acrylic panels but merely dent a polycarbonate panel of the same thickness.
Cost Comparison
Price is one of the first questions we hear from customers deciding between these two materials. Here is how the costs break down as of 2026.
For standard clear sheets, acrylic typically runs 25-35% less than polycarbonate at the same thickness. The exact gap depends on thickness, sheet size, and whether you are buying cut-to-size or full sheets.
Price Ranges by Thickness
Thin sheets (1/16" to 1/8") show the smallest dollar difference between the two materials because the raw material cost is a smaller portion of the total price. As thickness increases, the price gap widens.
A standard 24" x 48" clear acrylic sheet in 1/4" thickness typically costs between $30 and $50, depending on vendor and quantity. The same-size polycarbonate sheet runs $40 to $65. At 1/2" thickness, acrylic might cost $60 to $90 while polycarbonate runs $80 to $120.
These are rough retail ranges. Actual prices vary by supplier, quantity breaks, and whether the sheet is cast or extruded (for acrylic) or standard or UV-coated (for polycarbonate).
Total Cost of Ownership
The upfront price difference does not always tell the full story. Polycarbonate costs more per sheet, but if your acrylic panel cracks after two years in a high-impact location and needs replacement, the polycarbonate would have been cheaper in the long run. Consider the application environment, expected lifespan, and replacement difficulty when comparing total cost.
For indoor applications with low impact risk (displays, frames, signage), acrylic's lower price and better clarity make it the obvious value pick. For outdoor or high-impact applications, polycarbonate's higher initial cost often pays for itself by avoiding replacements.
Fabrication and Working Tips
Both acrylic and polycarbonate can be cut, drilled, bent, and bonded, but each material behaves differently during fabrication. Knowing these differences before you start a project saves time and avoids ruined sheets.
Cutting
Acrylic cuts cleanly on table saws, band saws, and laser cutters. Use fine-tooth blades (10-14 teeth per inch) and keep the protective film on during cutting to prevent scratches. Laser cutting produces flame-polished edges on acrylic that need no additional finishing.
Polycarbonate requires slower feed rates and generates more heat during cutting. On a laser cutter, polycarbonate can produce discolored or rough edges because the material melts rather than vaporizes cleanly. For the best results with polycarbonate, use a circular saw with a carbide-tipped blade and keep the speed moderate.
Drilling
Drill acrylic with bits specifically designed for plastic or modified twist bits (ground to a 60-degree point angle). Standard metal drill bits grab the material and can cause cracking. Always back the acrylic with a scrap piece of wood and drill at moderate speed.
Polycarbonate is forgiving when drilling. Standard HSS twist bits work fine. The material flexes instead of cracking, so you can drill near edges without the fracture risk you face with acrylic. Use light, consistent pressure and clear chips frequently.
Bending and Forming
Acrylic must be heated to approximately 320-340 degrees F (160-170 degrees C) before bending. At this temperature, it becomes pliable and can be formed over jigs or molds. Once cooled, it holds the new shape permanently. Strip heaters (line benders) are the standard tool for making clean bends in acrylic sheet.
Polycarbonate can be cold-bent to a tighter radius than acrylic without cracking. The minimum cold-bend radius is roughly 100 times the sheet thickness (a 1/8 inch sheet can bend to a 12.5 inch radius). For sharper bends, heat polycarbonate to 290-310 degrees F (143-154 degrees C). Polycarbonate's flexibility makes it popular for curved glazing and barrel vault skylights.
Bonding and Gluing
Acrylic bonds exceptionally well with solvent-based cements like Weld-On 3 or Weld-On 4. The solvent melts the surfaces together, creating a joint that is nearly as strong as the parent material. This is why acrylic dominates in aquarium construction and custom display fabrication.
Polycarbonate does not bond as easily with solvents. Methylene chloride-based cements can work, but the joints are weaker than those in acrylic. For structural polycarbonate assemblies, mechanical fasteners (screws, bolts, rivets with oversized holes for thermal expansion) are more reliable than adhesive bonds. Two-part epoxies and urethane adhesives also work well for non-structural polycarbonate joints.
Environmental and Safety Considerations
Both acrylic and polycarbonate are recyclable thermoplastics, but recycling infrastructure varies by region. Acrylic (recycling code 7 or "Other") is accepted at fewer facilities than common plastics like PET or HDPE. Polycarbonate is also code 7. Check with your local recycling program before assuming curbside pickup will accept either material.
From a safety standpoint, polycarbonate has an advantage in fire resistance. Standard polycarbonate self-extinguishes when the flame source is removed, earning a UL94 V-2 rating. With flame-retardant additives, it can achieve V-0 (the highest UL94 rating). Acrylic is combustible and will continue to burn once ignited. For applications in commercial buildings or public spaces where fire codes apply, polycarbonate may be required over acrylic.
Polycarbonate also performs better under sudden temperature changes. Acrylic can crack from thermal shock if rapidly cooled or heated. Polycarbonate's wider service temperature range (-40 degrees F to 240 degrees F) and lower brittleness make it more reliable in environments with rapid temperature fluctuations, like commercial freezer doors or outdoor enclosures that transition from cold nights to hot sun exposure.
Frequently Asked Questions
Is acrylic or polycarbonate better for outdoor use?
It depends on the risk of impact. Acrylic handles UV exposure better without coatings and stays clear for 10+ years outdoors. Polycarbonate needs UV coating but handles impacts from hail, branches, and vandalism far better. For a patio cover in a hail-prone area, choose polycarbonate. For outdoor signage in a sheltered location, acrylic is the better option.
Can you drill holes in acrylic and polycarbonate?
Yes, but the technique differs. Acrylic requires slow drill speeds and sharp bits designed for plastic. Drill too fast or use dull bits and the acrylic will crack or chip around the hole. Polycarbonate drills easily with standard bits and is much more forgiving. It will not crack during drilling.
Which material is easier to cut?
Acrylic cuts cleaner and produces polished edges on laser cutters and table saws. Polycarbonate tends to melt slightly during cutting, which can leave rougher edges that need finishing. For CNC routing and laser work, acrylic gives better results.
Does polycarbonate yellow over time?
Uncoated polycarbonate will yellow after prolonged sun exposure. Quality manufacturers apply a UV-protective coating to one or both sides, which prevents yellowing for 10+ years. Make sure you install UV-coated polycarbonate with the coated side facing outward. Our KASTLITE polycarbonate sheets include UV protection.
What is stronger, Lexan or Plexiglass?
Lexan is a brand name for polycarbonate. Plexiglass is a brand name for acrylic. Lexan (polycarbonate) is about 30 times stronger than Plexiglass (acrylic) when it comes to impact resistance. However, Plexiglass has better scratch resistance, higher optical clarity, and costs less.
Can I use acrylic as a replacement for glass windows?
Yes. Acrylic is a common glass replacement for windows, storm doors, and secondary glazing. It transmits more light than glass (92% vs. 90%), weighs half as much, and is 17 times more impact-resistant than standard glass. For high-security or high-impact window applications, polycarbonate is the better glass alternative.
Which plastic sheet is best for a DIY greenhouse?
Twin-wall polycarbonate is the standard for DIY greenhouses. It provides better insulation than single-wall acrylic or glass, resists hail and branch impacts, and transmits enough light for healthy plant growth. Single-wall polycarbonate or acrylic can work for cold frames or small hobby greenhouses in mild climates.
Where to Buy Acrylic and Polycarbonate Sheets
KASTLITE manufactures and ships both materials from Clearwater, Florida, to all 50 states. Our plastic sheet collection includes clear, colored, and specialty acrylic and polycarbonate in standard and custom sizes.
- Shop Acrylic Sheets (clear, colored, and custom cut-to-size)
- Shop Polycarbonate Sheets (clear, multi-wall, and UV-coated)
- Browse All DIY Plastics (acrylic, polycarbonate, ABS, PVC)
Not sure which material fits your project? Contact our team for a recommendation. We have helped customers select the right plastic sheet for applications from restaurant sneeze guards to industrial machine enclosures. You can also read our beginner's guide to ABS plastic sheets if you are considering other material options beyond acrylic and polycarbonate.