Acrylic and solid polycarbonate can look very similar, but they respond differently to knocks, scratches and fabrication. The best choice depends on what your sheet needs to withstand.

As a starting point, choose solid polycarbonate when impact resistance is the priority, and consider acrylic when clarity and surface appearance matter most. Understanding the differences will help you choose a material that suits the job.

Toughness and surface hardness are different things

Solid polycarbonate absorbs considerably more impact energy than acrylic. This makes it a practical option for vulnerable shed windows, protective panels and appropriately designed guards.

Acrylic is more brittle, so it is more likely to crack under a substantial impact. Its surface generally resists everyday scratching better than standard, uncoated polycarbonate, however. A harder surface does not necessarily mean a tougher sheet.

Where impact resistance and resistance to surface wear are both important, abrasion-resistant polycarbonate offers another option. Its protective coating improves performance, although it still needs careful handling and cleaning.

Clarity and appearance

Acrylic sheet offers excellent optical clarity and a glossy finish, making it popular for display covers, signs and decorative glazing.

Clear solid polycarbonate also provides good transparency. For everyday glazing projects, impact performance may be a more useful deciding factor than the small difference in light transmission. Where appearance is particularly important, compare samples of the actual products.

Polycarbonate vs acrylic: the technical comparison

These figures compare typical published properties for clear solid polycarbonate and extruded acrylic. They do not apply to multiwall or corrugated sheets, and specialist grades may perform differently.

Property	Solid polycarbonate	Extruded acrylic
Density	1.20g/cm³	1.19g/cm³
Calculated weight of a 4mm sheet	4.80kg/m²	4.76kg/m²
Visible light transmission	Approximately 89% for clear 3mm sheet	Approximately 92% for clear sheet
Tensile modulus — a measure of stiffness	2300MPa	3200MPa
Heat deflection temperature at 1.82MPa, ASTM D648	130°C	91°C
Thermal expansion per metre, per 1°C temperature increase	0.065mm	0.070mm

Typical manufacturer data, rather than guaranteed values for every sheet. Weight is calculated from density and thickness. Light transmission varies with thickness, colour and finish.

The figures show that weight is almost identical at the same thickness. Acrylic is stiffer, while polycarbonate’s main advantage is toughness: its ability to absorb impact without cracking as readily.

Both materials need room for thermal movement. For example, a 2m sheet experiencing a 40°C temperature increase would lengthen by approximately 5.2mm in polycarbonate or 5.6mm in acrylic. These calculated movements illustrate why fitting clearance matters; follow the requirements of your chosen glazing system.

Polycarbonate also has a higher heat deflection temperature in the quoted test. This measures deformation under a specified load, rather than a safe continuous operating temperature. It should not be treated as approval to install either material near a heat source.

Outdoor use and UV protection

Both materials can be suitable outdoors, but they achieve weathering resistance differently.

Acrylic is inherently resistant to UV exposure. Polycarbonate intended for long-term outdoor use normally incorporates a protective UV layer. Our standard solid polycarbonate range is UV2 protected, meaning protection is provided on both surfaces. Check specialist finishes separately.

UV resistance describes how a material withstands sunlight. It does not automatically tell you how much UV passes through it or whether it will reduce heat build-up. Read our UV protection guide for more detail.

Cutting, drilling and fitting

Polycarbonate is generally more forgiving during fabrication because it is less brittle. Acrylic can also be cut and drilled successfully, but it needs appropriate tooling, firm support and care around holes and edges.

With either material, use the specified fixing clearances and avoid overtightening. Cleaners, adhesives and sealants also need checking: incompatible products can cause clouding or fine stress cracks, particularly around fixings and bends.

Which should you choose?

For a display cover unlikely to suffer heavy knocks, acrylic may provide everything you need. For a workshop window exposed to accidental impact, solid polycarbonate is usually the more suitable starting point.

Compare the required thickness, dimensions and finish when assessing cost. Choosing a thinner sheet simply because the material is tougher can overlook the support and stiffness the finished panel needs.

At The Polycarbonate Store, we supply both materials. Contact our team with your intended use and measurements if you need help choosing.

FAQs

Is acrylic the same as polycarbonate?

No. Acrylic, also known as PMMA, and polycarbonate, often shortened to PC, are different thermoplastics. Their appearance can be similar, but their impact resistance, surface hardness and fabrication requirements differ.

If acrylic is stiffer, why is polycarbonate better for impact resistance?

Stiffness describes resistance to bending. Impact resistance describes how a material responds to a sudden strike. Acrylic is generally stiffer, but polycarbonate can absorb considerably more impact energy before breaking.

Can I replace acrylic with polycarbonate of the same thickness?

Sometimes, but it should not be assumed. Check the panel dimensions, supports, fixings and permitted deflection before substituting one material for the other. Greater impact resistance does not automatically allow a thinner sheet.

How many times stronger is polycarbonate than acrylic?

There is no single figure that applies to every product and test. Meaningful comparisons need matching test methods, specimen dimensions and conditions. A falling-weight impact result cannot be divided by an Izod impact result to produce a reliable “times stronger” claim.

Which is better for roofing?

Polycarbonate is widely used for roofing because of its impact resistance and the available roofing systems. Alongside solid sheets, multiwall polycarbonate offers an insulating channel structure. Choose the sheet and supporting system together rather than swapping materials solely on appearance.

Can I bend either material without heating it?

Some polycarbonate sheets can be cold curved within the manufacturer’s specified minimum radius. Acrylic generally requires controlled heating for forming and should not be forced into the same curve. Specialist coated sheets may have additional restrictions.

Can I use ordinary glass cleaner on either material?

Do not assume glass cleaner is suitable for plastic glazing. Some ingredients can damage the surface or cause stress cracking. Follow the manufacturer’s instructions; mild soap, lukewarm water and a clean, soft cloth are the usual starting point.