As someone who’s spent over a decade working with plastic materials here at Associated Plastics Tasmania, I’ve answered this question more times than I can count: “What’s the difference between acrylic and polycarbonate sheets?”
It’s one of the most common queries we receive from customers working on everything from home DIY projects to large commercial installations. While both materials might look similar at first glance, choosing between them can significantly impact the success of your project.
Let me walk you through the key differences based on my hands-on experience with these versatile materials.
Clarity and Appearance
When customers visit our Hobart showroom, many can’t immediately tell the difference between acrylic and polycarbonate just by looking at them. Both offer excellent clarity, but there are subtle differences:
Acrylic (Perspex):
- Offers superior optical clarity – about 92% light transmission
- Has a brilliant, glass-like appearance
- Available in countless colours and finishes (we stock everything from clear to opal, pastels and vibrant colours)
- Maintains its clarity over longer periods when used outdoors
Polycarbonate:
- Good optical clarity (about 88% light transmission)
- Slightly bluish or yellowish tint when viewed from the edge
- Fewer colour options are generally available
- Can develop a yellowish tint over time when exposed to UV light (though many now come with UV-resistant coatings)
I recall a customer who needed perfectly clear display cases for a local museum exhibition. After seeing both materials side-by-side, they immediately chose acrylic for its superior clarity and museum-grade appearance.
Strength and Impact Resistance
This is where the most significant difference lies and where making the right choice becomes crucial:
Acrylic (Perspex):
- Approximately 10-20 times stronger than a glass of equal thickness
- Can break with sufficient impact, forming sharp pieces
- More brittle than polycarbonate
- More susceptible to stress cracking if improperly machined
Polycarbonate:
- Virtually unbreakable – approximately 250 times stronger than glass and 30 times stronger than acrylic
- Extremely high-impact resistance
- Can withstand heavy blows without breaking
- Will deform rather than shatter when subjected to extreme force
I’ve personally demonstrated this difference to countless customers over the years. We had a Tasmanian builder come in needing material for a boat windscreen replacement. Though acrylic would have been cheaper and clearer, I recommended polycarbonate due to the punishing marine conditions. Two years later, he returned to thank me after his boat took a beating in rough seas – the polycarbonate windscreen had flexed but remained intact, potentially preventing serious injury.
Workability and Fabrication
Having fabricated both materials extensively in our workshop, I can tell you there are notable differences in how they handle:
Acrylic (Perspex):
- Easier to cut and machine with standard tools
- Polishes to a brilliant finish
- Can be flame polished on edges
- Bonds extremely well with solvent cement
- Less prone to scratching during fabrication
- Works beautifully with our laser cutting services
Polycarbonate:
- More difficult to machine without proper tools and techniques
- Requires slower cutting speeds to prevent melting
- It cannot be flame-polished
- More challenging to achieve perfect edge finishes
- Excellent for thermoforming (bending with heat)
- Better suited to our CNC router cutting service than laser cutting
We recently completed a project for a local aquarium that required complex bends and shapes. The polycarbonate’s superior flexibility during thermoforming allowed us to create seamless curved viewing panels that would have been nearly impossible with acrylic.
Weather Resistance and Durability
In Tasmania’s variable climate, this consideration is particularly important:
Acrylic (Perspex):
- Excellent UV resistance
- Does not yellow significantly over time (especially with modern formulations)
- More likely to crack or break under impact or extreme temperature changes
- Better long-term clarity in outdoor applications
- Typically has a 10-year warranty for outdoor use
Polycarbonate:
- More prone to yellowing unless treated with UV protective coating
- Superior temperature resistance (-40°C to 120°C)
- Better performance in extreme environments
- Excellent fire resistance (self-extinguishing)
- Typically has a shorter warranty for clarity retention outdoors
I’ve seen this play out with signage installations around Hobart. Acrylic signs typically maintain their appearance longer in normal conditions, while polycarbonate is the go-to for areas with risk of vandalism or extreme weather exposure.
Cost Considerations
Budget is always a factor, and there’s a clear difference here:
Acrylic (Perspex):
- Generally 30-40% less expensive than equivalent polycarbonate
- More cost-effective for most standard applications
- Better value when clarity is the primary consideration
Polycarbonate:
- Significantly more expensive
- Cost-effective when considering long-term durability in high-impact environments
- Value proposition improves in security or safety applications
A recent example comes to mind: we had a customer planning to install balcony balustrades at their coastal home. While polycarbonate would have provided marginally better wind resistance, we recommended acrylic based on their budget and the material’s excellent clarity and UV performance. The installation has performed beautifully for years while saving them thousands of dollars.
Common Applications: Where Each Shines
Based on the hundreds of projects we’ve supplied for across Tasmania and beyond, here’s where each material tends to excel:
Acrylic (Perspex) Excels For:
- Display cases and retail fixtures
- Picture framing and photo mounting
- Signage and point-of-sale displays
- Aquariums (thicker sheets)
- Decorative projects and furniture
- Light diffusion panels
- General glazing alternative to glass
- Boat windows in protected areas
Polycarbonate Excels For:
- Security glazing and shields
- Machine guards
- Sport facilities (hockey rinks, basketball backboards)
- Greenhouse and skylight glazing
- High-impact areas
- Bullet-resistant applications
- Noise reduction barriers
- Roofing applications
Making Your Selection: Questions I Always Ask Customers
When helping customers choose, I typically ask:
- Will the material be subject to impact or potential breakage?
- Is optical clarity your top priority?
- What’s your budget for the project?
- Will the material be exposed to outdoor conditions?
- Are there any special fabrication requirements?
Conclusion: Which Should You Choose?
After 45+ years of serving Tasmanians with custom plastic solutions, our experience at Associated Plastics Tasmania suggests:
Choose acrylic when:
- Optical clarity is paramount
- Cost is a significant factor
- UV resistance is needed
- The application is decorative or display-oriented
- You need extensive colour options
- The risk of impact is low to moderate
Choose polycarbonate when:
- Maximum impact resistance is essential
- The application involves safety or security
- The material will be subject to extreme conditions
- Flexibility and thermoforming capabilities are needed
- Fire resistance is required
- Weight reduction compared to glass is critical
Still unsure which material is right for your specific project? Drop into our showroom in Hobart, give us a call, or send us an email with your requirements. Our team has decades of combined experience working with both materials and can help you make the right choice for your specific application.
Remember, the best material isn’t always the strongest or the clearest – it’s the one that best meets your specific needs and budget.
This article was written by the fabrication team at Associated Plastics Tasmania, with over 45 years of experience in custom plastic solutions for Tasmanian homes and businesses.
