When you’re quoting a commercial glass project, the right material depends on more than just appearance. Strength, clarity, workability, lead time, budget, and the final application all matter – especially when the project calls for a glass alternative rather than traditional glass. Polycarbonate and acrylic sheets are two of the most common alternatives to glass.
Both are lightweight, transparent thermoplastics suitable for applications where standard glass isn’t necessary, practical, or cost-effective. But even these two have unique benefits that make them better-suited to certain commercial projects.
Below, we’ll compare polycarbonate versus acrylic sheets for commercial projects and walk through the factors to consider before choosing between the two.
Both polycarbonate and acrylic sheets are considered “plastic glass.” Both are suitable substitutes for a number of regular glass applications and offer improved security and public safety. You’ve probably talked about both materials by their brand names – polycarbonate is often referred to as “Lexan,” and acrylic as “Plexiglass.”
Both materials are clear, available in various thicknesses and sizes, and can be shaped into specific forms. They’re also both part of the thermoplastic family, which means they share some general characteristics, such as being moldable at certain temperatures.
However, their distinct chemical compositions and manufacturing processes lead to some notable contrasts.
Understanding the differences between polycarbonate and acrylic will help you make a more informed decision for your glass project. Below is a chart comparing these two popular alternatives.
|
Polycarbonate |
Acrylic |
|
|
Strength |
Stronger (250x stronger than traditional glass) |
Weaker, but still 17x stronger than traditional glass |
|
Weight |
Lightweight and similar to acrylic |
Lightweight and similar to polycarbonate |
|
Transparency |
Clear with a slight tint, prone to yellowing |
Clear, shiny, polishable if fade occurs |
|
Surface damage resistance |
More prone to scratching |
More prone to chipping and cracking |
|
Durability |
Better cold weather endurance |
Better UV-Ray endurance |
|
Workability |
Better suited for fabrication than acrylics, but takes more work to form |
More easily formable without losing strength |
|
Price |
Higher upfront cost, better long-term value |
Lower upfront cost, lower long-term value |
|
Applications |
High-impact, heavy-duty uses |
Low-impact protective uses |
Then, we’ll lay out eight key factors to evaluate when choosing one over the other:
1. StrengthPut up against each other, polycarbonate is stronger than acrylic. Less rigid and able to withstand temperature changes without breaking, polycarbonate sheets are ideal for some of the toughest jobs -- even providing protection against bullets.
While one is stronger and more durable than the other, both acrylic and polycarbonate sheets are stronger than standard glass. Compared to traditional glass, polycarbonate sheets are up to 250x stronger, while acrylic is only 17x stronger.
Compared to traditional glass, acrylic and polycarbonate sheets weigh about 50% less. When put side by side, acrylic and polycarbonate sheets with the same dimensions don’t tip the scales in one direction or the other."
To the naked eye, polycarbonate and acrylic both appear to boast the same clarity as glass alternatives for windows.
Upon closer inspection, polycarbonate does have a slight tint to it. When exposed to sunlight for long periods of time, that tint eventually turns yellow. And it’s impossible to restore the material to its original clarity.
Though only slightly clearer, acrylic does outshine polycarbonates on the appearance front in a few ways. Acrylic is a shinier material and can be polished to maintain its sheen. Should its transparency dull, you can also polish acrylic to restore its original appearance.
In addition, an experienced fabricator can grind the edges of acrylic pieces to the point where they’re almost visually nonexistent. This makes acrylic the preferred choice when edge clarity is part of the design intent — interior partitions, display cases, or any application where the glazing edge is exposed.
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In this category, one material isn’t better than the other. It comes down to the intended use and the type of surface-level damage each is susceptible to.
Polycarbonate sheets are more likely to fall victim to scratches that can’t be buffed out. On the other hand, acrylics are more prone to chip or even crack when subjected to strong impacts.
For indoor use, both materials work reliably for their intended roles. However, outdoor environments introduce challenges that may impact their performance.
Acrylic sheets are better suited for outdoor environments because their chemical properties help them resist sunlight, UV rays, warping, and discoloration. Conversely, polycarbonate sheets need an additional UV-resistant coating on both sides, since prolonged sun exposure can cause yellowing. On the other hand, polycarbonate sheets handle cold temperatures more effectively than acrylic. As a stronger material, polycarbonate is less prone to brittleness and cracking.
One factor worth noting for both polycarbonate and acrylic is that they expand and contract significantly more than glass — polycarbonate's coefficient of linear thermal expansion is roughly 6–7x that of glass. For large-format panels or exterior applications, glazing pocket depth, bite dimensions, and sealant selection need to account for this movement.
In comparing polycarbonate vs. acrylic, polycarbonate sheets are easier to work with -- but not in the sense you might think. Because polycarbonate sheets are stronger, they are better suited for fabrication than acrylics. Whether cut, drilled, or shaped, polycarbonate is less likely to break, though it does take more effort and skill to fabricate.
Acrylic’s comparative weakness, however, does make the material easier to form. In simplest terms, acrylic sheets won’t lose integrity or strength after being heated and molded into a shape.
When comparing polycarbonate vs. acrylic costs, acrylic is the cheaper alternative.
Because of its strength, durability, and the extra effort required during fabrication, polycarbonate costs more. Those factors contributing to its higher cost make it a better long-term investment.
Though easier to work with, acrylic is more prone to breaking. It’s a cheaper alternative to glass that is easier on your wallet to replace.
Due to their similarities, both polycarbonate and acrylic can be used for a variety of applications, such as windows, partitions, and sneeze guards.
Polycarbonate sheets, being the stronger of the two, are particularly well-suited for high-impact or heavy-duty uses, including:
While still durable and easier to shape, acrylic is a great glass alternative for safety applications like:
Though not the same as glass, polycarbonate and acrylic sheets do the same jobs and offer enhanced strength and protection. While no option is overall better than the other, polycarbonate is most often used for high-impact, heavy-duty applications. Acrylic is often used for less intensive commercial projects where impact isn’t as much of a concern.
When considering which glass alternative is best for your project, evaluate these eight factors against your intended use to make the best selection possible.
Working on a commercial project that calls for polycarbonate or acrylic? Our team can help you select the right material, confirm thickness and edge treatment requirements, and get you cut-to-size sheets when you need them. Request a quote below.
(Editor's note: This article was originally published in December 2020 and was recently updated.)