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.
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
Impact Resistance: Survives collisions and drops better than ABS, PETG, or PLA.
Thermal Stability: Withstands high-temperature environments (e.g., under-hood automotive parts).
Optical Clarity: Retains transparency post-printing, suitable for light diffusers or medical devices.
Chemical Durability: Resists degradation from oils, alcohols, and weak acids.
Electrical Insulation: Ideal for non-conductive housings in electronics.
Limitations of Polycarbonate
Print Complexity: Requires high-temperature hardware and enclosed printers.
UV Sensitivity: Degrades under prolonged sunlight unless coated.
Hygroscopic Behavior: Absorbs moisture rapidly, necessitating dry storage.
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
PC-ABS Blends: Combine PC’s strength with ABS’s.
PC-CF (Carbon Fiber): Enhances stiffness and heat resistance for aerospace and automotive uses.
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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