Have you ever gone to your glass vendor, explained your project, and been told to look at a plastic glass substitute instead?
For all its benefits, sometimes glass isn’t the right material for a job. Regular single-pane glass is heavy and fragile. It’s expensive to temper or laminate it for additional strength.
Like William of Ockham said, “Entia non sunt multiplicanda praeter necessitatem.” Or, paraphrased – the simplest answer is usually the best one.
If glass is too heavy, expensive, or weak for your project, don’t over-engineer it. Sometimes it pays to go simple and substitute in cost-effective acrylic or polycarbonate sheets.
Acrylic and polycarbonate are quickly becoming the go-to alternatives for glass in a variety of applications. This is because both materials offer numerous advantages over traditional glass:
Acrylic is a hard, clear plastic. Known commonly by one of its brand names – Plexiglas – it’s sometimes referred to by its chemical name: polymethyl methacrylate (PMMA).
Acrylic is a thermoplastic, meaning it’s meltable and recyclable. It’s also formable when heated.
Another thermoplastic, polycarbonate is formable when heated and recyclable – but, unlike acrylic, it’s also formable at room temperature. Manufacturers use press brakes to re-form polycarbonate sheets and heat them to a low temperature to set the shape.
Polycarbonate (PC) is often referred to by one of its brand names – Lexan.
Despite sharing many similarities, polycarbonate and acrylic have many differentiating traits to consider:
|
Acrylic |
Polycarbonate |
|
|
Strength |
17x stronger than glass |
250x stronger than glass |
|
Weight |
50% the weight of glass |
50% the weight of glass |
|
Transparency |
Clear and polishable |
Slight tint, not polishable |
|
Surface damage resistance |
Susceptible to chips and cracks upon impact |
Susceptible to scratches |
|
UV resistance |
UV resistant, does not discolor |
No UV resistance without added coating; yellow after prolonged sun exposure |
|
Weather resistance |
May crack under cold temperatures |
Suitable for all weather |
|
Workability |
Easier to form into custom shapes |
Best suited for fabrication due to thickness |
|
Price |
$ |
$$ |
Because they share a lot of the same characteristics, acrylic and polycarbonate are interchangeable in some situations. However, there’s a reason these two highly similar products exist: to meet specific needs.
In general, PC is favored for its impact resistance. Acrylic shines in its transparency.
As the stronger of the two glass alternatives, Lexan polycarbonate sheets are ideal for:
1. Bulletproof windows
2. Roofing
3. Greenhouse panels
4. Outdoor equipment windshields
Because of their similarities, Plexiglas and Lexan can be used for some of the same jobs, such as:
5. Windows
6. Partitions
7. Sneeze guards
Plexiglas is a suitable glass alternative for:
8. Display cases
9. Picture frame glass
Polycarbonate sheets are used for bulletproof windows because they’re extremely strong and impact resistant. They can withstand multiple hits from high-velocity bullets and other projectiles, making them ideal for security applications.
Polycarbonate sheeting is ideal for patio and deck roofs, awnings, and pergolas. Its impact resistance guards against falling branches, hail, and other windswept projectiles. Its weather resistance holds up to both heat and cold.
Because they’re lightweight, durable, and able to withstand harsh weather conditions while also allowing natural light through, clear polycarbonate sheets make great greenhouse panels.
Building a greenhouse with PC also costs less. In addition to savings on the sheets versus glass alternatives, the framing materials used can be lighter and less expensive.
Lexan is a better choice than glass for windshields on outdoor equipment because it’s lightweight, shatterproof, and highly impact resistant. Unlike glass, polycarbonate won’t shatter if hit by a hard or high-speed object.
Acrylic and polycarbonate sheets are used as windows because they offer excellent protection from the elements while also allowing natural light through them. Additionally, they’re lightweight and durable materials that can be easily cut into custom shapes or sizes without compromising the integrity of the window frame.
Remember: Acrylic/PMMA/Plexiglas has built-in UV resistance. Polycarbonate/PC/Lexan can be coated for UV protection, but isn’t UV resistant on its own.
Polycarbonate and acrylic are better choices than glass for partitions because they’re shatterproof and highly impact resistant, making them much safer to use.
Because they’re much lighter than glass and are impact- and shatter-resistant, acrylic and polycarbonate is preferred in restaurants and other settings requiring sneeze guards. They’re also more cost-effective than glass, and cheaper to replace.
Acrylic is an ideal material for custom retail display cases due to its lightweight, shatterproof, and transparent properties. Acrylic itself has a high clarity rating, meaning that items stored within the display case are viewable without obstruction. It softens light reflections, as well. Whereas glass display cases become mirror-like when lit, acrylic display cases have softer reflections and less glare. It also doesn’t yellow with age like Lexan.
Its shatterproof nature means there’s no risk of broken glass getting into merchandise or injuring customers. Furthermore, acrylic sheets are easier to cut into custom shapes and sizes than traditional glass due to their thermoplastic properties.
Plexiglas’ transparency also ensures that items stored within the display case are easily visible from outside, which helps to attract customers' attention. Additionally, acrylic provides better
Custom Plexiglas is the new preferred choice over glass to protect framed art and photographs. In this particular application, acrylic is more expensive up-front. However, its light weight reduces shipping costs and makes it easier to hang.
Its optical clarity is better than glass, and it's safer in the event a frame falls.
As glass substitutes, acrylic, and polycarbonate sheets continue to find new markets for their diverse applications. Both types of sheeting are lightweight, making them easier to install than traditional glass.
Key takeaways:
Are you ready to start sketching out your next Lexan or Plexiglas project? Head here to learn more about communicating your ideas clearly with your commercial glass partner: