Polycarbonate Rod

Polycarbonate rods are semi-transparent thermoplastic materials that exhibit high impact resistance, good machinability, and excellent electrical properties. They are lighter than glass and more dimensionally stable than acrylic over a wide temperature range. They can be used for various industrial applications that require durability and transparency.

Kusla supplies customed Polycarbonate Rods in different sizes and colors.

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Polycarbonate Rod Specification

DiameterOutside Diameter: 0.125 in – 8 in
LengthCustom
TEXTURE, SURFACE,PATTERNCustom
GradesMachine, Glass-Filled, Print Grade, General Purpose, Food Grade, FDA Compliant (Non UV Stabilized), Low Flammability, Flame Inhibiting, Class A Fire Rating, Sign Grade, Abrasion Resistant (AR 2), Light Diffusing, UV Resistant, IR Blocking, Containment Grade, Bullet Resistant, Optical, FMVSS Compliant, Antimicrobial
Types and ColorsClear, Natural, Black

Typical Properties of Polycarbonate

UNITSASTM TESTPOLYCARBONATE
Specific gravity (73°F)D7921.2
Light transmittance (transparency/clarity)%D100386
Heat deflection temperature @ 264 psi°FD648270
Tensile strengthpsiD6389,500
Flexural moduluspsiD790345,000
Izod impact (notched)ft-lbs/in of notchD25612.0 - 16.0
Maximum continuous service temperature in air°F240
Water absorption (immersion 24 hours)%D5700.15
Coefficient of linear thermal expansionin/in/°Fx10-5D6963.8

Choose Polycarbonate Rod For Your Program

  • Black Polycarbonate Rod
  • Solid Polycarbonate Rod
  • Round Polycarbonate Rod
  • polycarbonate welding rod
  • Multi-color Polycarbonate Rod
  • Clear Polycarbonate Rod
  • Thick Polycarbonate Rod
  • Square Polycarbonate Rod
  • Extruded Polycarbonate Rod

Main Benefit Of KUSLA Polycarbonate Rod

  • •265° F continuous use temperature
    •Transparent
    •Excellent toughness
    •Low moisture absorption
    •Superior electrical properties
    •Excellent UV resistance
    •Easily machined and fabricated
    •Glass fiber filed grades for improved strength and stiffness
    •High dielectric strength
    •Light weight
    •Wide range operating temperatures (-40° F to 280° F)
    •High impact resistance- virtually unbreakable
    •High clarity and light transmission

Frequently Asked Questions about Polycarbonate rod

Polycarbonate rods are semi-transparent thermoplastic materials that exhibit high impact resistance, good machinability, and excellent electrical properties. They are lighter than glass and more dimensionally stable than acrylic over a wide temperature range. They can be used for various industrial applications that require durability and transparency.

Some of the advantages of polycarbonate rod over other plastics are:

  • It has very high impact strength and can withstand shocks and drops without breaking.
  • It has excellent clarity and light transmission, making it suitable for optical applications.
  • It has good electrical insulation and flame retardancy, making it safe for electrical and electronic applications.
  • It has low moisture absorption and good chemical resistance, making it durable and versatile for various environments.
  • It has high thermal stability and can withstand temperatures up to 240°F (132°C) without deforming.
  • It is easy to machine and thermoform, making it adaptable for different shapes and sizes

Some of the disadvantages of polycarbonate rod are:

  • It is susceptible to UV degradation, meaning that it will yellow and crack over time when exposed to sunlight.
  • It is prone to scratches and marring, so it is not as durable as some other plastics.
  • It is more expensive to form than other plastics due to its structure.
  • It is flammable and has limited fire resistance, so it is not ideal for certain applications.
  • It cannot handle high temperatures, meaning that it can deform or lose its strength and durability in the heat.
  • It has low surface hardness and low modulus of elasticity, making it difficult to use for high load applications.

To choose the right size and shape of polycarbonate rod, you should consider the following factors:

  • The intended application and function of the rod. Different applications may require different sizes and shapes of polycarbonate rod to meet the specifications and performance requirements. For example, if you need a rod for optical purposes, you may want a clear and smooth rod with a precise diameter. If you need a rod for structural purposes, you may want a thicker and stronger rod with a suitable length.
  • The available dimensions and tolerances of the rod. Polycarbonate rod comes in various diameters and lengths, and you should check the availability and accuracy of the dimensions before buying. You should also check the tolerances of the rod, which indicate how much variation there is in the actual size of the rod compared to the nominal size. You should choose a rod with a tight tolerance if you need a precise fit or alignment.
  • The machinability and thermoformability of the rod. Polycarbonate rod is easy to machine and thermoform, meaning that you can cut, drill, bend, and shape it to your desired size and shape. However, you should also consider the tools and techniques that are suitable for working with polycarbonate rod, as well as the possible effects of machining and thermoforming on the properties and appearance of the rod. For example, you should use sharp tools and low feed rates to avoid melting or chipping the rod. You should also avoid overheating or overstretching the rod to prevent cracking or warping.

To cut and drill polycarbonate rod, you should follow these steps:

  • Mark the desired length and position of the rod using a pencil or a marker. You can use a ruler or a tape measure to ensure accuracy.
  • Secure the rod in a vise or a clamp to prevent it from moving or slipping. You can use a piece of wood or cloth to protect the rod from scratches or damage.
  • Use a fine-toothed saw or a hacksaw to cut the rod along the marked line. You can also use a circular saw or a band saw if you have one. Make sure to use a sharp blade and apply gentle pressure to avoid cracking or melting the rod.
  • Smooth the edges of the cut rod using a file, sandpaper, or a deburring tool. You can also use a flame polisher to remove any burrs or roughness.
  • Mark the desired location and size of the hole using a pencil or a marker. You can use a center punch to make a small indentation on the rod to guide the drill bit.
  • Use a drill bit designed for plastic with a sharp point and a back relief angle. You can also use a standard twist drill bit if you sharpen it properly. Make sure to use a low speed and moderate pressure to avoid overheating or cracking the rod.
  • Drill the hole through the rod using steady and even strokes. You can use cutting oil or water to lubricate the drill bit and reduce friction. You can also use a drill press if you have one for more accuracy and stability.
  • Clean the hole and remove any chips or shavings using compressed air, a brush, or a vacuum. You can also smooth the edges of the hole using a file, sandpaper, or a deburring tool.

To clean and polish polycarbonate rod, you should follow these steps:

  • Rinse off the rod with water to remove any dust or dirt. You can also use compressed air or a soft brush to blow off the debris. Never use a dry cloth or your hand to rub the rod, as this may scratch the surface.
  • Use a mild soap and water solution and a soft cloth or sponge to gently wipe the rod. You can also use a plastic cleaner such as Plexi-Clean, Novus #1, or Brillianize that are specially formulated for polycarbonate. Do not use abrasive cleaners, solvents, or ammonia-based products, as they may damage the rod.
  • Rinse the rod with water and dry it with a soft cloth or paper towel. Do not use a circular or swirling motion, as this may create swirl marks on the rod. Instead, use straight strokes along the length of the rod.
  • If the rod has light scratches, you can use a polishing paste such as Novus #2 or Xerapol to buff them away. Apply a small amount of polish on a clean, dry microfiber cloth and rub it over the scratch and the surrounding area in small circular motions. You can also use a patch disc or a buffing wheel attached to a drill for larger areas.
  • If the rod has deep scratches, you can use a heavier abrasive such as Novus #3 or sandpaper to reduce them. Start with a coarse grit and work your way up to a fine grit until the scratch is barely visible. Then follow with a polishing paste to restore the shine.
  • To protect the rod from future scratches and dust, you can apply a plastic polish or wax such as Novus #1 or Brillianize that will create a thin protective layer on the surface. Use a soft cloth to apply and buff the polish or wax according to the instructions.

To bond and glue polycarbonate rod, you should follow these steps:

  • Choose a suitable adhesive for polycarbonate, such as methyl methacrylate, epoxy, structural acrylic, or UV-curable adhesive. Make sure to read the instructions and safety precautions of the adhesive before using it.
  • Clean and dry the surfaces of the polycarbonate rod that you want to bond. You can use a mild soap and water solution and a soft cloth or sponge to remove any dirt or grease. Then rinse and dry the rod thoroughly.
  • Apply the adhesive to one or both surfaces of the polycarbonate rod, depending on the type of adhesive. If you are using a two-part adhesive, make sure to mix the components well and use a static mixing nozzle to ensure proper curing. If you are using a UV-curable adhesive, make sure to use a light source that matches the wavelength spectrum of the adhesive.
  • Press the surfaces together and hold them firmly until the adhesive sets. The curing time may vary depending on the type and amount of adhesive, the temperature and humidity, and the size and shape of the bond. Follow the manufacturer’s recommendations for optimal curing conditions.
  • Remove any excess adhesive with a knife or a cloth. You can also use a solvent or a polish to clean and smooth the bond area. Be careful not to damage or scratch the polycarbonate rod.

To bend and form polycarbonate rod, you should follow these steps:

  • Choose a suitable method for bending polycarbonate, such as cold line bending, brake bending, or thermoforming. Cold line bending is the simplest method that does not require heating, but it is limited to small angles and may cause stress cracking. Brake bending is a method that uses a metal punch and die to force the polycarbonate into a desired shape. Thermoforming is a method that uses heat and pressure or molds to create complex 3D shapes.
  • Prepare the polycarbonate rod for bending by cleaning and drying it. You can use a mild soap and water solution and a soft cloth or sponge to remove any dirt or grease. Then rinse and dry the rod thoroughly.
  • If you are using cold line bending, mark the desired angle and position of the bend on the rod using a pencil or a marker. Then secure the rod in a vise or a clamp and bend it rapidly along the marked line. You may need to overbend the rod by 20-40 degrees to compensate for springback.
  • If you are using brake bending, mark the desired shape and position of the bend on the rod using a pencil or a marker. Then place the rod between the punch and die of the brake machine and apply pressure until the rod conforms to the shape. You may need to adjust the pressure and angle of the machine depending on the thickness and stiffness of the rod.
  • If you are using thermoforming, heat the polycarbonate rod to its glass transition temperature, which is around 150°C (302°F). You can use an oven, a heat gun, or a hot water bath to heat the rod evenly. Then place the rod in a mold or a press and apply pressure until it takes the desired shape. You can also use vacuum forming or blow molding techniques to create hollow shapes.
  • Let the polycarbonate rod cool down slowly and evenly to avoid warping or cracking. You can use air cooling, water cooling, or annealing methods to cool the rod. Annealing is a process that involves heating and cooling the rod in a controlled manner to reduce internal stresses.

Polycarbonate rod has a wide range of applications in various industries due to its high impact resistance, good strength and stiffness, low moisture absorption, and excellent electrical properties. Some of the applications of polycarbonate rod are:

  • Optical devices and components, such as lenses, prisms, mirrors, light guides, and fiber optics
  • Electrical and electronic devices and components, such as connectors, switches, relays, sensors, and circuit boards
  • Mechanical and structural devices and components, such as gears, bearings, bushings, rollers, valves, impellers, and manifolds
  • Medical devices and components, such as surgical instruments, implants, catheters, and syringes
  • Food processing and packaging devices and components, such as trays, containers, bottles, and caps
  • Security and safety devices and components, such as face shields, helmets, goggles, bulletproof windows, and locks
  • Architectural and decorative devices and components, such as skylights, domes, signs, displays, and furniture

To store and handle polycarbonate rod, you should follow these steps:

  • Store the polycarbonate rod in a cool, dry, and well-ventilated place. Avoid exposure to direct sunlight, heat sources, or moisture. Keep the protective film or wrapping on the rod until ready to use.
  • Handle the polycarbonate rod with care and avoid dropping, dragging, or scratching it. Use gloves, tongs, or slings to lift and move the rod. Do not use hooks, chains, or wires that may damage the surface.
  • Clean the polycarbonate rod with a mild soap and water solution and a soft cloth or sponge. Rinse and dry the rod thoroughly. Do not use abrasive cleaners, solvents, or ammonia-based products that may harm the rod.
  • Polish the polycarbonate rod with a plastic polish or wax to restore its shine and protect it from scratches and dust. Use a soft cloth to apply and buff the polish or wax according to the instructions

Some of the safety precautions when working with polycarbonate rod are:

  • Wear appropriate personal protective equipment (PPE) such as gloves, goggles, masks, and aprons to protect yourself from dust, fumes, heat, and cuts.
  • Use proper ventilation and exhaust systems to remove any harmful decomposition products that may result from overheating or burning the polycarbonate rod.
  • Use sharp tools and low feed rates to avoid melting or chipping the polycarbonate rod. Do not use excessive force or speed that may cause friction or sparks.
  • Use cutting oil or water to lubricate the tools and reduce friction when cutting or drilling the polycarbonate rod. Do not use solvents or ammonia-based products that may damage the rod.
  • Avoid static electricity buildup on the polycarbonate rod by using antistatic mats, sprays, or wipes. Do not touch the rod with bare hands or metal objects that may cause sparks or shocks.
  • Dispose of any waste or scrap polycarbonate rod in accordance with local regulations. Do not burn or incinerate the rod as this may release toxic gases.

Polycarbonate rod is a recyclable plastic material that can be reused for various purposes. Some of the ways to recycle or dispose of polycarbonate rod are:

  • Sort the polycarbonate rod by type, size, or thickness and place it in a shredder machine. The shredded polycarbonate can be turned into granules that can be used for making new polycarbonate products.
  • Return the polycarbonate rod to the manufacturer or supplier that offers a buyback program. They may offer a discount or a credit for the returned polycarbonate material.
  • Find a recycling center that specializes in polycarbonate or plastic recycling. They may have the equipment and expertise to process and repurpose the polycarbonate rod.
  • Do not burn or incinerate the polycarbonate rod as this may release toxic gases. Follow the local regulations and guidelines for disposing of plastic waste.

Machine grade and extruded polycarbonate rod are two types of polycarbonate products that differ in their manufacturing process and properties.

  • Machine grade polycarbonate rod is produced by compression molding and has a higher molecular weight and better mechanical properties than extruded polycarbonate rod.
  • Machine grade polycarbonate rod also has tighter tolerances and less internal stress than extruded polycarbonate rod. Machine grade polycarbonate rod is suitable for applications that require high strength, stiffness, dimensional stability, and precision machining.
  • Extruded polycarbonate rod is produced by continuous extrusion and has a lower molecular weight and lower mechanical properties than machine grade polycarbonate rod.
  • Extruded polycarbonate rod also has wider tolerances and more internal stress than machine grade polycarbonate rod. Extruded polycarbonate rod is suitable for applications that require transparency, impact resistance, and thermoforming.

Clear and black polycarbonate rod are two types of polycarbonate products that differ in their color and light transmission. Clear polycarbonate rod is a transparent thermoplastic that allows light to pass through it. It is often used for optical applications such as lenses, prisms, light guides, and fiber optics. Black polycarbonate rod is an opaque thermoplastic that blocks light from passing through it. It is often used for electrical applications such as connectors, switches, relays, and sensors. Both clear and black polycarbonate rod have excellent impact resistance, good strength and stiffness, low moisture absorption, and good electrical properties.

Polycarbonate and acrylic rod are two types of clear plastic rods that have different properties and applications. Some of the main differences between polycarbonate and acrylic rod are:

  • Polycarbonate rod has higher impact resistance than acrylic rod, making it more suitable for applications that require durability and protection. Polycarbonate rod can withstand shocks and drops without breaking, while acrylic rod can crack or shatter under impact.
  • Acrylic rod has higher transparency than polycarbonate rod, making it more suitable for applications that require optical clarity and light transmission. Acrylic rod has a high gloss finish and is more scratch-resistant than polycarbonate rod, while polycarbonate rod is more prone to scratches and marring.
  • Acrylic rod is cheaper than polycarbonate rod, making it more economical for applications that do not require high strength or flexibility. Acrylic rod is also easier to machine and thermoform than polycarbonate rod, as it can be heated and molded to shape multiple times without losing its quality appearance.
  • Polycarbonate rod has higher heat resistance than acrylic rod, making it more suitable for applications that involve high temperatures or flames. Polycarbonate rod can withstand temperatures up to 240°F (132°C) without deforming, while acrylic rod can deform or melt at temperatures above 180°F (82°C).
  • Polycarbonate rod has higher chemical resistance than acrylic rod, making it more suitable for applications that involve exposure to acids, bases, or solvents. Polycarbonate rod can resist most chemicals without damage, while acrylic rod can be damaged by solvents or ammonia-based products.

The price of polycarbonate rod may vary depending on the size, color, grade, and supplier of the rod. the average price range of polycarbonate rod is between $1 to $60 per foot. However, this is only an estimate and the actual price may differ depending on various factors such as availability, demand, shipping costs, taxes, and discounts. Therefore, it is advisable to contact the us directly for a more accurate quote and to compare different options before making a purchase.

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