Introduction
PC (polycarbonate) is a type of amorphous thermoplastic known for its high impact resistance and transparency. It also demonstrates good electrical insulation properties and moderate chemical resistance.
Available in a range of rod and plate formats, PC is commonly used in the automotive industry for the production of instrument panels, pumps, valves and more. It is also used in other sectors for the production of protective gear, medical devices, intermal mechanical parts and more.
Surface Finish
Electroplating
Electroplating can be functional, decorative or corrosion-related. Many industries use the process, including the automotive sector, in which chrome-plating of steel automobile parts is common.
Bead blasting
Bead blasting results in parts with a smooth surface with a matte texture. Used mainly for visual applications and can be followed by other surface treatments.
Painting
Painting the surface of a part improves its aesthetic appearance and can provide brand recognition to consumers. In addition, painting can have a protective effect on parts.
Polishing
Polishing is the process of creating a smooth and shiny surface, either through physical rubbing of the part or by chemical interference. The process produces a surface with significant specular reflection, but in some materials is able to reduce diffuse reflection.
Manufacturability
Tolerance
- Standard: (+/-) 125 µm -Achievable: (+/-) 100 µm , (+/-) 50 µm
Wall Thickness
- The minimum wall thickness should be at least 1 mm for machined parts. - 2 mm is suggested for better strength and 2.5 mm for a rigid wall.
Pocket depth
- Pocket depth should be up to 3 times the diameter of the end mill
Engraving
- Engraving is preferable to embossing - For the clear, legible text consider fonts such as Arial or Gothic - Design letter strands with a width of at least 2 mm
Internal Radii
- The minimum internal radii possible is 1 mm - In general, internal radii dimensions depend on the depth of pocket being milled
Holes
- Use standard drill bit sizes - Minimum of 1 mm in diameter
Threads
- Use standard metric inserts - Smallest threaded insert possible is M2
Design Recommendations
Min Wall Thickness
0.5 mm
Min End Mill Size
0.8 mm (0.03 in)
Min Drill Size
0.5 mm (0.02 in)
Max Part Size
1200 x 500 x 152 mm [(x,y,z] (mill)
152 x 394 mm [d,h] (lathe)
Undercuts
Square profile, full radius, dovetail profiles
Radii : Depth
Depth must not exceed 12x drill bit diameter.
For end mills, depth must not exceed 10x drill bit diameter.
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