How to Form Polycarbonate Panels

Polycarbonate is sturdy plastic that is used for everything from optical lenses to windscreens on motorcycles. It also has many home applications such as shelving, protective screening or windows. Many people prefer it instead of glass since it is difficult to break or chip, yet is still transparent. You can purchase polycarbonate panels from plastic supply companies. With the help of some well-placed heat you can form polycarbonate into just about any shape needed for your own projects.

Things You'll Need

• Line bender
• 1/8-inch polycarbonate panels
• Router

Instructions

1. Remove the protective sheeting over the polycarbonate panel. If the film is paper, remove all of it before forming the panels. If it is plastic, you can leave it in place during heating.

2. Place the panel on the line bender. The line bender heats only a narrow area across your polycarbonate panel, so you should place your panel so that the heat is focused only in the area you want to form.

3. Wait for the panel to soften. As the panel heats, it will curl and relax, indicating that it is softening. At this point, try to bend the panel to see if it is soft enough for forming. If it is ready, the panel should bend easily into a new shape. If it does not bend easily, let it sit on the line bender for another minute or two before trying again.

4. Remove the panel from the heat. After forming the panel into your preferred shape, take it off of the line bender to cool. Polycarbonate cools and hardens within a few minutes, so your new shape sets up quickly.

Tips & Warnings

• Since polycarbonate absorbs moisture easily, this technique works best for 1/8-inch panels and thinner. Thicker panels tend to hold more moisture, causing bubbling during the heating process. If you have thicker panels, use a router on the bend line to thin the material down to 1/8 of an inch.

References

• Tap Plastics: How to Bend Plastic
• Makrolon Polycarbonate Sheets: Fabrication Guide