How To Glue Polycarbonate (PC)

What is Polycarbonate?

Polycarbonate also known as PC or Polycarb and commonly referred to by brand names such as Lexan® is a clear, high-performance thermoplastic widely used in industrial applications. Polycarbonate is valued for its exceptional impact resistance, high optical clarity, UV resistance and excellent heat resistance, making it far more durable than acrylic in demanding environments. 

What adhesives can bond polycarbonate?

Polycarbonate can be bonded using a variety of industrial adhesives like methacrylates, cyanoacrylates, solvent adhesives, UV adhesives and epoxies. Which adhesive is used greatly depends on the application, including factors such as required bond strength, clarity or adhesive colour, curing speed, environmental exposure, flexibility required and whether the bond is primarily structural or aesthetic.

Instant Adhesives (Cyanoacrylates)

Strengths	Extremely fast fixture, high shear strength, no mixing (single part), great for high-speed production lines and low odour / low bloom (no fogging) variants available for aesthetic appeal.
Limitations	Limited gap filling capability without activators, lower impact and peel strength compared to other structural adhesives, standard grades can bloom (white powdery residue) which aesthetically is not good for polycarbonate.
Most Suitable	All grades of NEXTITE Instant Adhesives work well with polycarbonate, special mention to low bloom/ low odour alkoxy cyanoacrylates like NEXTITE 503 or NEXTITE 560 will have the added benefit of low bloom (fogging/ white powdery residue) and NEXTITE 535 for clear rubber filled for some added flexibility.

 

Methacrylates (MMA)

Strengths	Structural adhesive, multi material bonding, toughened and flexible bond, various fixture times, good gap filling, widely used in industry manufacturing.
Limitations	No clear multi material variants available, generally viscosity is high, stronger odour, exothermic reaction (although limited).
Most Suitable	AB200 (fast cure, high strength), AB210 (medium cure, high strength), AB290 (Clear Polycarbonate Bonder), AB422 (medium cure, high toughness), AB560 (long cure, high viscosity, high toughness).

 

UV Adhesives

Strengths	Extremely high clarity joints that are bubble and blush free, easy to do extremely high-quality polycarbonate joinery, high joint strength, set the adhesive whenever you are ready.
Limitations	Limited outdoor environmental exposure, higher set up cost.
Most Suitable	ACRI-BOND UV1035 (Wicking Grade), ACRI-BOND UV2046 (Medium Viscosity), ACRI-BOND UV3232 (Thick Viscosity).

 

Solvent Adhesives

Strengths	Strong bonding of polycarbonate through chemically softening it and fusing it together, fast initial tack, exceptional clarity, cost effective.
Limitations	Joints often have small bubbles if used incorrectly, limited gap filling even with thickened grades, surface preparation is key to good joints.
Most Suitable	ACRI-BOND 105 (Water Thin, Wicking Grade), ACRI-BOND 110 (Thickened Slower Set), ACRI-BOND 125 (Thickened Faster Set).

 

Epoxy Adhesives

Strengths	Very high strength, transparent options available, excellent chemical and temperature resistance, gap filling, controlled cure.
Limitations	Most grades are not very flexible, can only use two component epoxies (single part, heat cure ones will damage polycarbonate in the process), epoxies can yellow overtime, surface preparation required.

 

MS Polymers

Strengths	Flexible elastic bond, excellent weather and UV resistance, clear grades crystal clear, low odour
Limitations	Lower structural strength, slower cure, not good for precision applications

 

What Industries is polycarbonate used in? 

In fabrication and manufacturing, polycarbonate is widely chosen for its versatility. It is easy to work with and can be cut, drilled, polished, thermoformed and bonded with industrial adhesives to produce many final products.

Common uses of material

• Polycarbonate is used in many industries including:
• Safety Glazing and Machine Guards
• Protective Screens, Barriers and Shields
• Signage and Display for High Temp Climates
• Automotive components
• Electrical enclosures and housings
• Medical devices and equipment
• Roofing and skylights 
• Industrial covers, housings and inspection panels

Challenges with polycarbonate

• Sensitive to solvents
• Stress cracking, from excessive stress or using the wrong solvent cleaners
• Adhesive must be matched for purpose of application
• Transparent grades of polycarbonate will require a transparent adhesive for aesthetic appearance

Properties of Polycarbonate

• Surface Energy: 42 mJ / m²
• Temperature Resistance: -40°C to 115°C
• Softening Point: 145°C
• Often Transparent or Semi Transparent

Surface Preparation

Proper surface preparation is critical to achieving a strong and reliable bond when working with polycarbonate. Begin by lightly wiping the bonding area with a dedicated plastic cleaner such as ACRI-BOND CLEANER or NEXTITE PROPREP Surface Preparation Cleaner. This removes surface contaminants including dust, oils and residual adhesive that can interfere with bond strength. Allow the cleaner to fully evaporate before applying any adhesive.

Polycarbonate, like many thermoplastics, is highly sensitive to solvents. Avoid using acetone or similar strong solvent cleaners, as they will cause surface crazing, cracking, discolouration and permanent damage that compromises both appearance and bond integrity. Using polycarbonate-safe cleaners like isopropyl alcohol ensures the surface remains intact and properly prepared for bonding. 

Summary

Choosing the best industrial adhesive to bond polycarbonate comes down to understanding the application requirements and performance required from the joint.

If you would like to speak to our expert team about your next project, please contact us for tailored advice and product recommendations to suit your application.