Perspex vs Polycarbonate (Lexan)
Originally posted 11 December 2018 — updated 17 June 2026
Perspex and polycarbonate look nearly identical on the shelf — both are clear, rigid, lightweight plastic sheets — but they're completely different polymers with very different strengths. Picking the wrong one wastes money at best and fails in service at worst. This guide compares them side-by-side so you can choose the right sheet for your job the first time.
Quick answer: Perspex® is cast acrylic (PMMA), the clearer, more scratch-resistant, more UV-stable, easier-to-fabricate option. Lexan® is polycarbonate (PC), the tougher, more heat-resistant, harder-to-break option. Acrylic for optics, signage and outdoor glazing; polycarbonate for impact, security and heat.
At a Glance: Perspex vs Polycarbonate vs Lexan
"Lexan vs Perspex" is the same comparison as "polycarbonate vs Perspex" — Lexan is just a brand name for SABIC's polycarbonate sheet. Equally, Perspex is the premium brand of cast acrylic. Both branded sheets compete against generic acrylic and polycarbonate from a dozen other mills, but the material properties are governed by the polymer, not the brand.
| Property | Perspex® (Acrylic / PMMA) | Lexan® (Polycarbonate / PC) |
|---|---|---|
| Light transmission | 92% | 88–89% |
| Impact strength vs glass | 10–17× | ≈ 250× |
| UV resistance | 30-year warranty (cast) | 10-year warranty (UV2 grade) |
| Max continuous service temp | 80–90 °C | 115–120 °C |
| Scratch resistance | Better — can be polished out | Lower — hard to repair |
| Cold bend radius | Not recommended | ≈ 175× sheet thickness |
| Laser cutting | Yes — flame-polished edge | No — scorches & releases fumes |
| Solvent bonding | Yes (dichloromethane / Weld-On 16) | Yes (THF / ACRI-Bond 105) |
| Thermoforming temp | 160–175 °C — easy | 175–195 °C — needs drying |
| Fire rating | Combustible | Self-extinguishing (V-2 / V-0) |
| Density | 1.19 g/cm³ | 1.20 g/cm³ |
| Relative cost (same thickness) | 1× | ≈ 1.3–1.5× |
UV Resistance & Outdoor Clarity
This is the single biggest reason Perspex wins for permanent outdoor glazing in Australia. Cast Perspex acrylic carries a 30-year warranty against yellowing, with UV stabilisers built through the entire sheet. Polycarbonate needs a sacrificial UV-protective film co-extruded onto one or both faces (UV2 grade) and is typically warranted for 10 years against yellowing and breakage.
Light transmission also favours Perspex — 92% vs around 89% for polycarbonate — and it stays clearer for longer because it doesn't yellow under UV. For signage faces, skylights, pool fencing infills and balustrade panels that need to look new in a decade, Perspex is the more honest long-term choice.
Impact Strength & Safety
Polycarbonate is in a different league for impact. At roughly 250× the impact resistance of glass and around 25× that of acrylic, it's the standard for machine guards, security glazing, riot shields and any application where someone might hit, kick or throw something at the sheet. Polycarbonate doesn't shatter — it deforms.
Acrylic is still 10–17× tougher than glass and won't break in normal display, signage or framing service. But under a hammer blow or a flying tool, acrylic will eventually crack while polycarbonate keeps absorbing the energy. If your spec sheet includes the word "vandal-resistant" or "ballistic", you're spec'ing polycarbonate.
Heat & Fire Performance
Polycarbonate has a noticeable heat-resistance advantage — a continuous service temperature of around 115–120 °C compared to 80–90 °C for cast Perspex. It's also self-extinguishing (UL94 V-2 or V-0 depending on grade), where standard acrylic is fully combustible. For light fittings, oven inspection windows and any application close to a heat source, polycarbonate is the safer pick. For a deeper dive see our guide to Perspex heat resistance.
Cutting, Routing & Laser
Both materials cut cleanly on CNC routers and panel saws using tungsten-carbide tooling. Perspex has one major fabrication advantage: it laser-cuts perfectly. A laser leaves a fire-polished, transparent edge that needs no further finishing — ideal for signage, awards, retail displays and short-run prototypes.
Polycarbonate cannot be laser-cut. The cut edge yellows, the kerf scorches, and the process releases chlorine-containing fumes. Polycarbonate is cut with jigsaws, panel saws, CNC routers and waterjet only.
Heat Bending & Thermoforming
Perspex bends crisply on a strip-heater at 160–170 °C and thermoforms easily for vacuum-formed domes, channel-letter faces and curved displays — see our thermoforming service. Polycarbonate needs higher temperatures (175–195 °C), pre-drying to prevent surface blemishes, and cools faster, making it harder to work without specialised equipment.
Polishing & Bonding
Acrylic edges can be flame-polished with a hydrogen torch, diamond-polished on a machine, or finished with progressive wet-and-dry sanding. Polycarbonate edges cannot be flame-polished — heat melts the surface badly — but they can be diamond-polished or solvent-finished to a matt clarity.
Both materials solvent-bond well, but they use different chemistry. Perspex bonds with dichloromethane or thickened glues like Weld-On 16 and ACRI-Bond 110. Polycarbonate bonds with tetrahydrofuran (THF) or ACRI-Bond 105. The two glue systems aren't interchangeable.
Cost — Sheet Price vs Spec'd Thickness
Sheet-for-sheet at the same thickness, polycarbonate is roughly 25–35% more expensive than Perspex. But because polycarbonate is so much stronger, you can sometimes drop a thickness — for example, spec 3mm polycarbonate in place of 4.5mm Perspex for a machine guard — which narrows the gap considerably. For pure display or signage applications where impact isn't a concern, Perspex is almost always the more economical choice.
When To Choose Perspex (Acrylic)
- Outdoor signage, lightboxes and channel-letter faces
- Pool fencing infills and balustrade panels
- Picture framing, art mounting and museum glazing
- Retail and POS displays, sneeze guards, donation boxes
- Skylights, splashbacks and architectural feature panels
- Anything that needs to be laser-cut, polished or bonded into clean assemblies
- Vacuum-formed and thermoformed shapes — domes, helmets, displays
When To Choose Polycarbonate (Lexan)
- Machine guards, robot cell screens and safety enclosures
- Security glazing, retail anti-ram screens, bullet-resistant assemblies
- Patio roofing, pergola covers and greenhouse glazing (UV2 grade)
- Industrial inspection windows near heat sources
- Cold-bent curves and tight-radius forms without thermoforming
- Sports facilities — squash courts, hockey arena dashers
- Anywhere a sheet needs to take repeated impact without breaking
The Bottom Line
If you're glazing a sign, framing a print, building a display or fencing a pool — choose Perspex. It's clearer, more UV-stable, easier to fabricate and cheaper. If you're guarding a machine, building a roof, blocking a vandal or surviving heat — choose polycarbonate. Both materials are stocked, cut to size, routed and fabricated daily at our Gold Coast workshop.
Frequently Asked Questions
What's the difference between Perspex and polycarbonate?
Perspex is a brand of cast acrylic (PMMA). Polycarbonate (sold as Lexan or Makrolon) is a completely different polymer. Perspex is clearer, more scratch-resistant, UV-stable for 30+ years and easier to polish or laser-cut. Polycarbonate is about 25× more impact-resistant, handles higher temperatures and can be cold-bent. Perspex wins on optics and outdoor longevity; polycarbonate wins on toughness and heat.
Is Perspex the same as Lexan?
No — they're different materials. Perspex® is acrylic (PMMA), made by ICI/Lucite. Lexan® is polycarbonate (PC), made by SABIC (originally GE). They look similar but Lexan is roughly 25× tougher than Perspex, while Perspex has better optical clarity, UV stability and scratch resistance.
Which is stronger — Perspex or polycarbonate?
Polycarbonate is stronger by a large margin. Perspex acrylic is about 10–17× the impact strength of glass; polycarbonate is around 250× the impact strength of glass. For security glazing, machine guards or anything that gets hit, polycarbonate is the right choice. For displays, signage and pool fencing, Perspex is more than strong enough.
Which is more UV-resistant?
Cast Perspex acrylic carries a 30-year warranty against yellowing and is the better outdoor material long-term. Polycarbonate needs a UV-protective coating (UV2 grade) and is typically warranted for 10 years against yellowing and breakage. For permanent outdoor glazing in Australian sun, Perspex usually wins.
Which is cheaper — Perspex or polycarbonate?
Perspex acrylic is roughly 25–35% cheaper than polycarbonate of the same thickness. However, because polycarbonate is so much tougher, you can often spec a thinner sheet (e.g. 3mm polycarbonate in place of 4.5mm Perspex) and close some of the gap.
Can both be cut on a laser?
Perspex laser-cuts beautifully with a flame-polished edge straight off the machine. Polycarbonate cannot be laser-cut — it scorches, yellows and releases chlorine fumes. Polycarbonate is cut with CNC routers, panel saws or jigsaws instead.
Can polycarbonate be glued like Perspex?
Both can be solvent-bonded but with different chemistry. Perspex uses dichloromethane or thickened adhesives like Weld-On 16 / ACRI-Bond 110. Polycarbonate uses tetrahydrofuran or ACRI-Bond 105. Mixing the two glue systems will not give a strong joint.