Polycarbonate (PC)

Polycarbonate (PC) is a premium engineering thermoplastic renowned for its metal-like impact strength, exceptional dimensional stability, high temperature resistance, and glass-like optical clarity. At Jucheng Precision, an ISO 9001:2015, ISO 13485, and IATF 16949 certified manufacturer, we specialize in custom PC injection molding for demanding medical and automotive applications. Backed by 35+ advanced molding presses (50-650T) and 25+ in-house 5-axis CNC machines, we strictly control internal stresses and knit lines through optimized molding parameters. We provide a free DFM analysis within 24 hours, ensuring high-quality optical components validated by Zeiss CMM inspection.

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Our available materials

PC-Covestro Makrolon 2407

PC-Covestro Makrolon 2407 is a low-viscosity, UV-stabilized polycarbonate resin developed by Covestro, featuring an integrated easy mold release package for high-speed, automated production. Boasting a melt volume-flow rate (MVR) of 19 cm³/10 min (at 300°C/1.2kg) and outstanding structural toughness (notched Izod of 65 kJ/m²), this grade is optimized for thin-walled outdoor housings, transparent lenses, and electrical enclosures exposed to sunlight. Jucheng Precision, operating under IATF 16949 and ISO 9001 frameworks, specializes in molding Makrolon 2407 with zero cosmetic defects. Powered by 5-axis CNC-machined mirror S136 tool cavities, we prevent polymer degradation and eliminate weld lines, verified by Zeiss CMM inspection.

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PC-Covestro Makrolon 2805

PC-Covestro Makrolon 2805 is a medium-viscosity, amorphous polycarbonate resin developed by Covestro, equipped with an internal mold release agent for efficient demolding. Boasting a melt volume-flow rate (MVR) of 9.0 cm³/10 min (at 300°C/1.2kg) and extreme mechanical toughness (notched Izod of 85 kJ/m²), this grade is optimized for high-impact structural panels, safety shields, and industrial enclosures requiring high stress-crack resistance. Jucheng Precision, under IATF 16949 and ISO 9001 quality frameworks, specializes in molding Makrolon 2805 to deliver zero-defect parts. Backed by 5-axis CNC-machined S136 tool cavities and 35+ advanced presses, we control thermal stresses and eliminate weld lines, verified by Zeiss CMM inspection.

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PC-Covestro Makrolon Rx1805

Maintaining absolute structural clarity and high impact strength under repeated gamma-radiation sterilization and aggressive clinical lipid exposure requires a specialized amorphous polymer, which Covestro’s Makrolon Rx1805 delivers through its unreinforced, medical-grade polycarbonate matrix. Certified to USP Class VI and ISO 10993 biocompatibility standards, this premium easy-release resin provides outstanding tensile yield strength (66 MPa) and a high heat deflection temperature (HDT) of 125°C. Jucheng Precision, operating under strict ISO 13485 medical device certified frameworks, specializes in cleanroom molding of Makrolon Rx1805. Utilizing 5-axis CNC-machined S136 stainless steel tooling and pressurized water controllers, we eliminate internal residual molding stresses, delivering high-purity medical components verified by Zeiss CMM.

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PC-Sabic Lexan 141R

PC-Sabic Lexan 141R is an amorphous, non-halogenated polycarbonate resin engineered by SABIC, featuring an integrated internal mold release agent for clean, high-speed ejection. With a stable melt flow rate of 10.5 g/10 min and a density of 1.20 g/cm³, this grade is the global standard for high-transparency optical diffusers, automotive headlamp lenses, and durable electronic connectors. Jucheng Precision, under IATF 16949 and ISO 9001 frameworks, specializes in low-stress injection molding of Lexan 141R. Utilizing our five-axis CNC-machined conformal cooling toolings, we effectively prevent weld lines and eliminate residual thermal stresses, ensuring zero-defect components verified by Zeiss CMM inspection.

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PC-SABIC Lexan 3412

Achieving metal-like structural stiffness and exceptionally low thermal expansion in high-precision electrical and automotive housings without adding excessive weight requires a specialized composite, which SABIC’s Lexan 3412 delivers. This 20% glass fiber reinforced polycarbonate (PC-GF20) grade provides an impressive tensile modulus of 5,500 MPa and a heat deflection temperature (HDT) of 135°C, ensuring extreme dimensional stability under continuous mechanical load. Jucheng Precision, operating under IATF 16949 and ISO 9001 quality systems, specializes in high-precision injection molding of Lexan 3412. Utilizing 5-axis CNC-machined S136 stainless steel tooling and pressurized cooling, we control its anisotropic shrinkage (0.25%-0.45%) and prevent float fiber defects, delivering structurally flawless components verified by Zeiss CMM.

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PC-SABIC Lexan 940A

Securing reliable structural flammability safety and premium dielectric isolation in complex electronic housings without compromising mechanical drop-toughness requires an elite material, which SABIC’s LEXAN™ 940A delivers through its unreinforced, medium-viscosity flame-retardant polycarbonate matrix. Featuring a density of 1.21 g/cm³ and a glass transition temperature (Tg) of 150°C, this amorphous grade achieves an outstanding UL 94 V-0 flammability rating down to 1.0mm and a 5VA rating at 3.0mm. Jucheng Precision, operating under strict IATF 16949 and ISO 9001 frameworks, specializes in precision injection molding of Lexan 940A. Backed by 35+ advanced presses and in-house five-axis CNC-machined tooling, we control its low isotropic shrinkage (0.5%-0.7%), delivering flawless electrical enclosures verified by Zeiss CMM.

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PC-Teijin Panlite L-1250Y

PC-Teijin Panlite L-1250Y is a medium-viscosity, general-purpose polycarbonate resin developed by Teijin, formulated with integrated easy-release additives for high-yield precision molding. Featuring a melt volume-flow rate (MVR) of 8.0 cm³/10 min (at 300°C/1.2kg) and an ISO Charpy notched impact strength of 76 kJ/m², this grade offers a high refractive index of 1.585 and 88% light transmittance. Jucheng Precision, under IATF 16949 and ISO 9001 quality frameworks, specializes in molding Panlite L-1250Y for optical and industrial components. Using 5-axis CNC-machined S136 tool cavities and 35+ advanced presses, we control thermal stress and ensure uniform crystallization, verified by Zeiss CMM inspection.

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PC/ABS-Covestro Bayblend FR3010

Securing non-halogenated environmental compliance alongside high heat resistance and impact toughness in smart home enclosures and electric vehicle (EV) charging stations requires a specialized amorphous blend, which Covestro’s Bayblend FR3010 delivers. This flame-retardant PC/ABS alloy integrates polycarbonate's structural strength with ABS's easy flowability, achieving an exceptional UL 94 V-0 fire rating at 1.5mm and a 5VA rating at 2.0mm. Jucheng Precision, under IATF 16949 and ISO 9001 frameworks, specializes in precision injection molding of Bayblend FR3010. Utilizing S136 stainless steel molds, we control its low isotropic shrinkage (0.5%-0.7%) and manage volatile gas release, delivering flat, blemish-free electronic covers verified by Zeiss CMM.

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Comprehensive Polycarbonate (PC) Grades We Mold

We process premium-grade Polycarbonate resins from world-class compounders to meet high-clarity, high-strength, and fire-resistant structural requirements:

PC Material Class Typical Brand & Grade Key Characteristics & Advantages
Optical / High Flow • Sabic Lexan 141R / HF1110
• Covestro Makrolon 2407 / 2805
• Teijin Panlite L-1250Y
Exceptional optical clarity, light transmission (up to 90%), and high melt flow. UV-stabilized options available. Ideal for light guides, lenses, and safety goggles.
Flame Retardant (FR) • Sabic Lexan 940A / 943A
• Covestro Makrolon 6557
• Teijin Panlite LN-1250G
UL 94 V-0 non-chlorinated and non-brominated flame retardant ratings. Excellent impact retention. Perfect for electronic housings, switches, and industrial enclosures.
Medical Grade • Sabic Lexan HP1 / HP2
• Covestro Makrolon Rx1805 / Rx2440
ISO 10993 and USP Class VI compliant. Highly resistant to gamma radiation, ETO, and autoclave sterilization. Suited for surgical tools, dialyzers, and fluid connectors.
Glass-Filled Reinforced • Sabic Lexan 3412 (20% GF)
• Mitsubishi Iupilon GS-2030 (30% GF)
Reinforced with glass fibers for drastically increased flexural strength, tensile modulus, and thermal deformation resistance. Applied in structural gears, frames, and automotive brackets.

Applicable Molding Processes for Polycarbonate (PC)

Because Polycarbonate possesses high mechanical rigidity and high viscosity, it requires scientific process profiling:

Molding Process Process Suitability & Application
Standard Injection Molding Excellent. Highly recommended for clear optical lenses, protective face shields, and high-strength industrial enclosures.
Thin-Wall Molding Moderate to Good. Requires specialized high-flow PC resins and high-pressure injection to fill thin-walled designs without freeze-off.
Insert Molding Excellent. Ideal for encapsulating metal threaded inserts or connectors directly into heavy-duty electrical components to prevent weld-line stress.
Overmolding / Multi-Shot Excellent. Frequently overmolded with TPU or TPE to create rubber-like soft-touch grips on clear medical syringe handles or rugged enclosures.

Polycarbonate (PC) Injection Molding Technical Guide

Polycarbonate possesses high melt viscosity and is highly sensitive to moisture. Inadequate drying or poorly controlled thermal cycles can result in micro-cracks or loss of optical clarity:

  • Pre-Drying: PC is highly hygroscopic. Moisture levels must be kept below 0.02% to prevent hydrolytic degradation. We dry the raw resin in desiccant dryers at 120°C (248°F) for 3–4 hours prior to molding.
  • Melt Temperature: Processed at high temperatures, typically between 280°C and 320°C (536°F to 608°F). Thermal degradation can occur if temperatures exceed 340°C.
  • Mold Temperature: Mold temperatures must be kept high, ranging from 80°C to 120°C (176°F to 248°F). This minimizes internal stresses, prevents knit lines, and ensures a highly polished surface.
  • Draft Angles: Because PC is exceptionally rigid and contracts tightly onto core pins during cooling, generous draft angles of 1.5° to 2° are necessary to prevent ejection stress marks.
  • Molding Pressure: Due to PC’s high viscosity, significant injection and holding pressures are applied. Proper packing is mandatory to counteract the 0.5%–0.7% volumetric shrinkage and eliminate voiding in thick walls.

Key Application Industries for Molded PC Parts

  • Medical Devices (ISO 13485 Certified): Hemodialysis dialyzer housings, surgical instrument handles, clear fluid connectors, blood filter casings, and inhaler components.
  • Automotive Lighting (IATF 16949 Certified): Headlamp lenses, interior ambient light guides, rear light covers, dashboard buttons, and structural lens assemblies.
  • Electrical & Electronics: High-voltage connector blocks, electricity meter housings, transparent cover panels, switch boxes, and LED diffusers.
  • Consumer & Safety Products: Protective safety goggles, riot shields, bulletproof panels, clear water containers, and structural drone components.

Material Properties

Density 1.19 - 1.22 g/cm³
Melt Mass-Flow Rate (MFR) (300°C/1.2kg) 3.0 - 60 g/10 min
Light Transmission (Optical Clear) 88 - 91 %
Tensile Strength at Yield 55 - 75 MPa
Tensile Elongation at Break 50 - 120 %
Flexural Modulus 2,100 - 2,500 MPa
Izod Impact Strength (Notched, 23°C) 500 - 850 J/m
Rockwell Hardness (R-Scale) 118 - 125 -
Melting Temperature 145 - 150 °C
Heat Deflection Temperature (HDT @ 0.45 MPa) 130 - 140 °C
Linear Mold Shrinkage 0.5 - 0.7 %
Dielectric Strength 18 - 30 kV/mm
Volume Resistivity 1.0E+16 Ohm·cm
Maximum Part Size 1000 x 800 mm
Minimum Part Size 1 x 1 mm