Polycarbonate (PC) Injection Molding
High-impact, transparent thermoplastic. Excellent for applications requiring optical clarity and durability.
PC Properties
Key characteristics of polycarbonate material.
High Impact
Excellent impact resistance, virtually unbreakable compared to glass.
Transparent
Optical clarity, glass-like appearance, various tints available.
Heat Resistant
High heat deflection temperature, good for elevated temperature use.
Polycarbonate Material Options
Different PC formulations for specific applications.
Standard PC
General purpose polycarbonate, excellent clarity and impact strength.
UV Stabilized
Resistance to yellowing and degradation from sunlight exposure.
Flame Retardant
UL94 V-0 rated grades for electrical and electronic applications.
Glass-Filled PC
Enhanced stiffness and dimensional stability with glass fiber.
Optical Grade
Highest clarity for lenses, displays, and optical applications.
Medical Grade
Biocompatible, sterilizable grades for medical applications.
Polycarbonate Applications
Common applications for polycarbonate injection molding.
Transparency Applications
- Safety glasses and face shields
- Machine guards and windows
- Lighting lenses and covers
- Display screens and panels
- Instrument dials and gauges
- Architectural glazing
Durability Applications
- Electronic device housings
- Automotive lenses and covers
- Helmets and protective gear
- Appliance windows and doors
- Industrial equipment covers
- Food processing equipment
Our Polycarbonate Injection Molding Capabilities
Expert PC manufacturing from optical lenses to bullet-resistant windows. Precision, clarity, and strength.
Optical Clarity
Achieve 89-91% light transmission with optical grade PC.
- - 89-91% light transmission
- • Low haze (<1%) options
- - Various tints available
High Impact Strength
250-600% higher impact resistance than acrylic or glass.
- - 15-20 kJ/m² impact strength
- - Bullet-resistant grades
- - Low-temperature performance
Heat Resistance
HDT up to 138°C for high-temperature applications.
- - 125-138°C heat deflection
- - Continuous use to 115°C
- - Flame retardant options
Precision Molding
Tight tolerances for optical and engineering applications.
- - ±0.02mm critical tolerances
- - Optical finishing available
- - Clean room capable
Medical Grade
ISO 10993 biocompatible and sterilizable PC.
- - USP Class VI certified
- - Gamma/EO sterilizable
- - Full traceability
Flame Retardant
UL94 V-0 and V-1 ratings for electrical applications.
- - UL94 V-0 available
- - 5VA rated options
- - Glow wire compliant
Proven Polycarbonate Manufacturing Excellence
From safety equipment to medical devices, our PC parts deliver unmatched performance.
Medical Device Manufacturer
ISO 13485 certified production of transparent medical device housings. Zero defects over 2 million units.
Industrial Safety Supplier
Ballistic-rated face shields and safety goggles. Exceeds ANSI Z87.1 and EN166 standards.
Consumer Electronics Brand
Ultra-clear lens covers for smartphone cameras. 0.05mm tolerance with anti-reflective coating compatibility.
Quality Certifications & Testing
Certifications
- ISO 9001:2015 Quality Management
- ISO 13485 Medical Devices
- IATF 16949 Automotive Compliant
- UL94 Flame Rating Certification
- ANSI Z87.1 Safety Eyewear
Testing Capabilities
- Optical Clarity & Haze Testing
- Impact Resistance (Izod/Charpy)
- Heat Deflection Temperature
- UV Weathering Testing
- FTIR Material Verification
Polycarbonate Injection Molding FAQ
Expert answers to common questions about polycarbonate material selection and manufacturing
For Engineers
What's the best wall thickness for PC parts?
Recommended wall thickness is 1.5-3.5mm for PC. PC flows better than ABS but has higher shrink rates (0.5-0.7%). Thin walls risk brittleness; thick walls cause sink marks. Our DFM optimizes for your specific geometry.
How does PC compare to acrylic for transparent parts?
PC offers 30x higher impact strength than acrylic and better heat resistance (138°C vs 100°C HDT). Acrylic provides better optical clarity (92% vs 89%) and is more scratch-resistant. PC is better for safety-critical applications; acrylic for displays and lenses.
Can you achieve optical quality surfaces on PC parts?
Yes, we offer SPI A-2 polished molds for optical applications. For lens-quality parts, we use specialized optical grade PC with 89-91% transmission and less than 1% haze. Post-mold polishing and anti-reflective coating options available.
What are the moisture sensitivity considerations for PC?
PC is hygroscopic and requires drying at 120°C for 4-6 hours before molding. Moisture content must be below 0.02%. Wet PC causes splay, bubbles, and degraded impact strength. We maintain strict drying protocols and moisture verification.
For Procurement
What PC material brands do you offer?
We source from top suppliers: Bayer (Makrolon), SABIC (Lexan), LG Chem (Lucem), and Teijin (Panlite). All grades available with full traceability and lot-specific data sheets. Medical and optical grades from certified suppliers.
What are the lead times for PC tooling and parts?
Prototype molds: 7-15 days. Production molds: 4-6 weeks (due to tighter tolerances). Production parts: 2-3 weeks. Optical molds require additional polishing time (5-7 days). Rush services available with premium pricing.
Do you offer custom PC color matching?
Yes, we offer custom color matching using masterbatch from major suppliers. Clear, transparent tints, and opaque colors available. We match Pantone, RAL, or your sample. Small minimums for prototype colors, volume pricing for production.
What's your quality guarantee for PC parts?
Parts meet specs or we replace free. 99.7% first-pass yield backed by material certification, process SPC, and CMM verification. Optical parts undergo light transmission and haze testing. Full PPAP support for automotive.
For Decision Makers
Why choose CoreLMould for PC injection molding?
15+ years polycarbonate expertise, optical-grade capabilities, ISO 13485 medical certification, and 99.7% first-pass yield. We offer competitive pricing, fast optical tooling, and single-source responsibility for complex transparent parts.
What industries do you serve with PC parts?
Medical devices (ISO 13485), safety equipment (ANSI Z87.1), electronics (optical lenses), automotive (light covers), industrial (machine guards), and consumer products. From startups to Fortune 500, 1 unit to 10M+.
How do you handle PC material traceability?
Full lot traceability from raw material to finished part. Each batch provides supplier COA, manufacturing date, and quality data. Barcode tracking through production. Available for medical (MDR compliance) and automotive (PPAP) requirements.
Can you support long-term PC production programs?
Yes, we offer multi-year supply agreements with fixed pricing, dedicated inventory (Kanban), and mold ownership options. Stable supply chain with dual-source material strategy ensures uninterrupted production for your programs.
Polycarbonate Injection Molding Case Studies
Real projects demonstrating our PC capabilities
Medical Device Housings
ISO 13485 certified transparent housings with zero defects over 2 million units.
Safety Equipment
Ballistic-rated face shields exceeding ANSI Z87.1 and EN166 standards.
Camera Lens Covers
Ultra-clear lens covers with ±0.05mm tolerance for smartphones.
Our Manufacturing Facilities
State-of-the-art equipment and skilled workforce ensuring high-quality production
Mold & Tooling Base
5-axis CNC, EDM, and precision tooling manufacturing
Precision Molding
45+ injection molding machines from 50T to 1000T
Assembly
Complete product assembly from sub-assemblies to finished goods
Precision CNC
High-precision machining with tolerance up to ±0.005mm
EDM Processing
Quality lab with CMM and advanced inspection
Mold Assembly
Skilled technicians with 15+ years experience in mold assembly
Ready to Start Your Project?
Get started with a free quote. High-impact, transparent polycarbonate parts.