Polycarbonate Grades: Lexan vs Makrolon vs Tuffak vs GF30

Polycarbonate is sold under multiple trade names — Lexan (SABIC), Makrolon (Covestro), and Tuffak (Plaskolite) — that are largely interchangeable for general applications but diverge significantly in specialty formulations. Knowing which grade to specify determines performance at the service condition: UV-exposed outdoor glazing requires a stabilized grade; machine guards in abrasive environments need a hard-coat; high-temperature structural components need glass-fill. This page breaks down each grade family and when to use it.

At a glance:

• Lexan 9034 (SABIC): industry-standard general-purpose grade; baseline for all comparisons
• Makrolon AR (Covestro): abrasion-resistant hard-coat, ANSI Z87.1 qualified
• Tuffak (Plaskolite): equivalent GP performance at competitive pricing
• PC-GF30: 30% glass fiber for stiffness and elevated-temperature performance; opaque
• UV-stabilized grades: Makrolon UV, Lexan SL, Tuffak A — rated 5–10 year outdoor life
• Flame-retardant grades: UL 94 V-0 compounds for electrical enclosure applications

Grade Overview Table

Lexan 9034 (SABIC)

Lexan 9034 is the general-purpose polycarbonate sheet grade from SABIC (formerly GE Plastics) and is the most widely specified PC in North American industrial and commercial markets. It is the reference against which other grades are measured.

Properties

Optical: 88% light transmission, <1% haze in clear form. Available in clear, bronze, gray smoke, white, and black. Impact: 18 ft-lb/in notched Izod — the same as generic PC. Tensile: 9,500 psi. No UV stabilizer in standard form; UV-stabilized version is marketed as Lexan SL.

When to Specify

Lexan 9034 is the default for indoor machine guards, interior glazing, and thermoformed enclosure components where UV exposure and abrasion are not requirements. Makrolon GP or Tuffak GP substitutes without performance change.

Makrolon AR and Lexan Margard (Abrasion-Resistant Grades)

Uncoated polycarbonate scratches readily — this is the material's most cited weakness in abrasive or high-traffic applications. Abrasion-resistant grades apply a cured silicone hard-coat to one or both sheet faces during the manufacturing process.

Hard-Coat Performance

Makrolon AR passes ASTM D1044 (Taber Abrasion) at 5 mg weight loss per 500 cycles with a CS-17F wheel — significantly better than uncoated PC at 15–25 mg per the same test. For ANSI Z87.1 (eye and face protection), AR-coated grades meet the abrasion resistance requirement for safety eyewear substrates.

The hard-coat does not change the substrate's impact properties — Izod remains 18 ft-lb/in. It also does not significantly affect optical transmission (remains ~87–88%).

Limitations

Hard-coat grades cannot be thermoformed or line-bent without cracking the coating. Bonding with solvent cements on the coated face is ineffective — use mechanical fasteners or framing.

Tuffak (Plaskolite)

Tuffak is Plaskolite's polycarbonate brand, produced to ASTM D3935 and dimensionally interchangeable with Lexan 9034 and Makrolon GP. It is sold in the same sheet sizes, thickness range (0.030" to 1.000"), and color options.

Tuffak vs. Lexan: Practical Differences

There is no measurable performance difference between Tuffak and Lexan 9034 in general-purpose applications — both meet ASTM D3935 Type P1, Grade 1. Tuffak typically prices 5–15% below Lexan on equivalent thicknesses. Tuffak A (UV-stabilized, co-extruded cap layer) is a competitive alternative to Makrolon UV and Lexan SL for 10-year outdoor service.

PC-GF30 (30% Glass Fiber Filled)

PC-GF30 is polycarbonate compounded with 30% short glass fiber. The glass reinforcement changes the property profile substantially:

When to Use GF30

PC-GF30 is used where stiffness and elevated temperature performance matter and optical clarity is not required. Typical applications: structural brackets, motor housings, lamp bezels, and automotive chassis components. The trade-off is significant: impact drops from 18 to 3 ft-lb/in — it is a rigid engineering compound, not a tough one. Do not specify for impact-critical applications.

UV-Stabilized Grades

For outdoor service, UV stabilization is mandatory. The three primary options:

All three prevent the photooxidation yellowing and surface embrittlement that occurs in general-purpose grades within 6–12 months of direct sunlight exposure. The UV cap layer is on one face (the weather-facing side) — the sheet must be installed with the UV cap facing outward, marked at the mill with a notation on the masking film.

UL 94 V-0 Flame-Retardant Grades

Standard PC is UL 94 V-2 (self-extinguishes within 30 seconds, may drip). V-0 grades self-extinguish in < 10 seconds without flaming drips — required by UL 508A, and NEC Article 300 junction box materials. V-0 PC uses halogen-free phosphate flame retardants and is typically opaque. For electrical enclosure panels where flammability compliance is primary, V-0 PC sheet is the correct specification.

See the full polycarbonate specifications page for UL listing numbers and corresponding NEMA/IEC ratings.

Grade Selection Guide

Need help selecting between general-purpose and specialty grades? See the polycarbonate properties guide for detailed mechanical and optical data. For fabrication parameters by grade, the machining and fabrication page covers hard-coat-specific limitations. For comparison against non-PC materials, review acrylic vs. polycarbonate or the PETG and ABS options at the comparisons index.

More related guides

Cross-cluster suggestions to help shoppers and engineers explore adjacent topics:

Applications

• Machine Guards
• Marine Outdoor

Industries

• Marine

Compare to other materials

• Ultem Vs. Polycarbonate
• Polycarbonate Vs. Acrylic
• Polycarbonate Vs. Abs

Frequently asked questions — Polycarbonate FAQ