Polyester vs. Polycarbonate Materials

With the exception of a few select materials, the choice materials are typically between Polyester and Polycarbonate.

So what are the differences between Polyester and Polycarbonate material? Here is a breakdown of 5 characteristics that show the slight difference between the materials.

Cost:
This is typically the most commonly asked question when figuring out the difference. The cost difference between the two is so minimal that it typically does not factor into the decision. However technically speaking polycarbonate is marginally lower in price.

Analysis: The cost of the two should not factor as much as other aspects of the material, but if it is Polycarbonate is the less expensive material.

Size:
Polyester ranges from 5 mil (.005) – 10 mil (.010). Polycarbonate ranges from 5 mil (.005) – 60 mil (.060) or higher.

Analysis: Thickness may or may not be a factor in material selection? Typically most overlays are between the 5 – 10 mil range. If you go higher in thickness things like durability are more important than tactile feel. However in respect to actuating a membrane switch, any material above 10 mil (0.010) is not recommended.

Longest Lasting
Polyester material can withstand 2,000,000 actuations, is chemical resistant to household cleaners, scratch resistant, graffiti resistant, resistant to alcohol and acid, and overall has a greater resistance to a broader range of chemicals than polycarbonate. On the other hand polycarbonate can withstand 250,000 actuations, does have chemical resistance but is limited, scratch enhanced but not resistant, and polycarbonate can come in much thicker sizes (up to 60 mil) making it more durable.

Analysis: Both materials are extremely durable, in most cases lasting for years in typical environments. Choosing between the two based on longevity would depend on what your product would value most. Typically the overlay material is one of the last things fail, but Polyester material will last longer.

The Best looking
Polycarbonate can remain clear above 10 (0.010) mil. Polycarbonate is extremely easily and cleanly printed on all thicknesses. When die cut it, it cuts easier around the edges and embosses cleanly because of its flexibility. Polycarbonate has excellent color stability in light or white colors. Polyester offers a more consistent gloss and textured surface. Polyester offers a very attractive appearance.

Analysis: Both are great graphic applications and very receptive to all inks. Polycarbonate has a slight edge cosmetically.

Details
Polyester material is the most commonly used base material. Polyester cannot be torn. All circuitry must be done on polyester. Polyester can withstand higher temperature but is flammable. Polycarbonate is flame retardant and meets vertical burn test and will not drip material. Polycarbonate is more flexible. Both can have UV inks. Both materials are ink receptive. Both have the same gloss levels of 100,90,75,66,40,35,20%. Both are easily embossable. Both are ink receptive.

Analysis: Both materials have their own advantages and are the two best materials on the market. When considering which material is right, weighing these advantages is important.

Email me at patg@sensigraphics.com for ideas on future articles.