PC

Also referred to as Polycarbonate

Polycarbonate (PC) is a high-performance thermoplastic revered for its exceptional strength, heat resistance, and optical clarity. Often used in bulletproof glass and aerospace components, PC brings industrial-grade durability to 3D printing. While challenging to print, its unique properties make it indispensable for functional prototypes, automotive parts, and translucent applications requiring resilience.

Polymaker's PolyLite™ PC

What Is Polycarbonate?

Polycarbonate is a transparent thermoplastic with high heat resistance and very high impact resistance, capable of withstanding forces that shatter glass or acrylic. Its key attributes include:

  • High Tensile Strength: Comparable to concrete, with a tensile strength of 70–75 MPa.

  • Heat Resistance: Maintains structural integrity up to 150°C (glass transition temperature) and heat deflection temperatures exceeding 115°C.

  • Optical Clarity: Transmits light effectively, ideal for lenses, light guides, and transparent housings.

  • Chemical Resistance: Withstands oils, solvents, and fuels, suitable for industrial environments.

Printing with Polycarbonate: Challenges and Solutions

PC’s demanding nature requires precise calibration and hardware modifications.

Optimal Settings

  • Nozzle Temperature: 260–310°C (start at 265°C for standard PC, increase for composites).

  • Print Speed: 30–60 mm/s (slower speeds enhance layer adhesion).

  • Retraction: 1–2 mm at 20–30 mm/s to minimize stringing.

  • Cooling Fan: 0% (excessive cooling causes warping).

Material Preparation

  • Drying: Preheat filament at 70–80°C for 6–8 hours to remove moisture (PC is highly hygroscopic).

  • Storage: Keep in airtight containers with desiccant to prevent reabsorption.

Common Challenges

  • Warping: Mitigated by enclosed printers, heated beds, and slow first-layer speeds.

  • Stringing/Oozing: Fine-tune retraction and enable coasting in slicer settings.

  • Layer Adhesion: Higher nozzle temperatures, larger diameter nozzles, high chamber temperatures, and slower speeds improve bonding.

Advantages of Polycarbonate

  1. Impact Resistance: Survives collisions and drops better than ABS, PETG, or PLA.

  2. Thermal Stability: Withstands high-temperature environments (e.g., under-hood automotive parts).

  3. Optical Clarity: Retains transparency post-printing, suitable for light diffusers or medical devices.

  4. Chemical Durability: Resists degradation from oils, alcohols, and weak acids.

  5. Electrical Insulation: Ideal for non-conductive housings in electronics.

Limitations of Polycarbonate

  1. Print Complexity: Requires high-temperature hardware and enclosed printers.

  2. UV Sensitivity: Degrades under prolonged sunlight unless coated.

  3. Hygroscopic Behavior: Absorbs moisture rapidly, necessitating dry storage.

  4. Post-Processing: Difficult to sand or smooth; machining or vapor polishing required.

Applications of Polycarbonate

  • Automotive: Headlight housings, dash components, and engine bay fixtures.

  • Electronics: Transparent enclosures, connectors, and insulating components.

  • Medical: Surgical guides, sterilization-resistant tools, and imaging devices.

  • Industrial: Jigs, fixtures, and machinery parts exposed to heat or chemicals.

  • Consumer Goods: Durable phone cases, protective gear, and high-stress toys.

Reinforced Polycarbonate Variants

  1. PC-ABS Blends: Combine PC’s strength with ABS’s.

  2. PC-CF (Carbon Fiber): Enhances stiffness and heat resistance for aerospace and automotive uses.

  3. PC-ISO (Medical Grade): Biocompatible and sterilizable for healthcare applications.

Requirements to Print PC

This can vary drastically depending on the type of nylon and the manufacturer requirements. Generally speaking though - you should have:

  • Nozzle: All-metal hotend capable of 260–310°C (higher temps improve layer bonding).

  • Bed: Heated to 90–120°C with PEI, BuildTak, or adhesive-coated glass for adhesion. Magigoo PC recommended.

  • Enclosure: Maintains ambient temperatures of 60–70°C to prevent warping and delamination. Some polycarbonate formulas require up to 90°C chamber temps, something impossible for most consumer grade printers.

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