Polycarbonate Specifications: Thickness, Sizes & Standards
Polycarbonate sheet, rod, and tube are produced to published ASTM standards with defined thickness tolerances, slab dimensions, and optical requirements. Knowing these specifications prevents ordering errors and ensures the material meets applicable safety and regulatory listings — UL 94 for electrical, ANSI Z87.1 for PPE, and UL 752 for ballistic glazing. This page consolidates the critical dimensional, tolerance, and certification data engineers and buyers need.
At a glance:
- Sheet: ASTM D3935; standard slab 48″ × 96″; thicknesses 0.020" to 1.000"
- Thickness tolerances: ±10% below 0.250"; ±7% at 0.250" and above
- Rod: ASTM D5927; diameters 0.250" to 6.000"; centerless ground finish standard
- UL 94 V-2 rating applies to general-purpose grades at ≥0.060" thickness
- UL 752 bullet-resistance levels specify laminate thicknesses and interlayer counts
- ANSI Z87.1 applies to eye/face protection substrates; requires AR-coated grade
- CSA B44.1/ASME A17.5 for elevator cab glazing applications
Sheet Specifications
ASTM D3935 — Standard Sheet
Polycarbonate flat sheet is produced to ASTM D3935, "Standard Specification for Polycarbonate (PC) Unfilled and Reinforced Material." This standard defines:
- Type P1: general purpose, unfilled
- Type P3: UV-stabilized
- Type P4: impact-modified
- Grade 1: clear optical (transmission ≥ 85%)
- Grade 2: colored / translucent
All general-purpose clear stock — Lexan 9034, Makrolon GP, Tuffak GP — is Type P1, Grade 1. UV-stabilized grades (Makrolon UV, Lexan SL, Tuffak A) are Type P3.
Standard Sheet Sizes
| Sheet Size | Common Applications |
|---|---|
| 48″ × 96″ (4′ × 8′) | Standard slab, all industrial use |
| 48″ × 120″ (4′ × 10′) | Extended panels, door glazing |
| 60″ × 96″ (5′ × 8′) | Wider panels for machine guards |
| 72″ × 96″ (6′ × 8′) | Large-format architectural glazing |
| 48″ × 48″ half sheet | Reduced stock, small-run fabrication |
Custom slab sizes are available from most distributors on lead time. Oversized sheets (up to 72″ × 144″) are available from certain mills but require special freight handling.
Thickness Range and Availability
| Nominal Thickness | Available As | Tolerance |
|---|---|---|
| 0.020" (0.5mm) | Film roll, some sheet | ±15% |
| 0.030" (0.75mm) | Sheet (flexible) | ±12% |
| 0.060" (1.5mm) | Standard stock | ±10% |
| 0.080" (2mm) | Standard stock | ±10% |
| 0.093" (2.4mm) | Standard stock | ±10% |
| 0.118" (3mm) | Standard stock | ±10% |
| 0.177" (4.5mm) | Standard stock | ±10% |
| 0.220" (5.5mm) | Standard stock | ±10% |
| 0.250" (6.35mm) | Standard stock | ±7% |
| 0.375" (9.5mm) | Standard stock | ±7% |
| 0.500" (12.7mm) | Standard stock | ±7% |
| 0.750" (19mm) | Standard stock (less common) | ±7% |
| 1.000" (25.4mm) | Special order at some distributors | ±7% |
Nominal thickness is the stated dimension; actual thickness will vary within tolerance. For critical fit applications — glazing into routed channels, for example — measure actual thickness at multiple points before finalizing channel width. Plan for ±10% variation at thicknesses below 0.250".
Weight per Square Foot by Thickness
| Thickness | Weight (lb/ft²) |
|---|---|
| 0.060" | 0.32 |
| 0.118" | 0.63 |
| 0.220" | 1.18 |
| 0.250" | 1.34 |
| 0.375" | 2.01 |
| 0.500" | 2.68 |
| 0.750" | 4.03 |
| 1.000" | 5.37 |
A 48″ × 96″ sheet at 0.250" weighs approximately 26.6 lb; at 0.500" it is 53.2 lb.
Rod and Tube Specifications
ASTM D5927 — Rod
Polycarbonate rod is produced to ASTM D5927. Standard finish is centerless ground, cut to 24", 36", 48", or random 8–12 ft lengths.
| Diameter Range | Surface Finish | Notes |
|---|---|---|
| 0.250" – 1.000" | Centerless ground | Wide availability |
| 1.125" – 3.000" | As-extruded or ground | Most distributors stock to 3" |
| 3.500" – 6.000" | As-extruded | Special order |
Diameter tolerances (ASTM D5927): ±0.005" for ≤ 1.000"; ±0.015" for > 1.000".
Tube
Polycarbonate tube is available in standard IPS OD dimensions from 0.500" to 8.000" with wall thicknesses from 0.062" to 0.500". Applications include sight glasses, light tubes, and custom structural parts.
UL and Safety Certifications
UL 94 Flame Classification
| Classification | Self-Extinguish Time | Dripping | Thickness |
|---|---|---|---|
| V-2 | ≤ 30 sec | Allowed (non-igniting) | ≥ 0.060" GP grades |
| V-0 | ≤ 10 sec | No drip | FR-compound grades |
| HB | Slow burn | N/A | Thin GP sections |
GP polycarbonate achieves V-2 at ≥ 0.060"; below that, HB. V-0 requires a flame-retardant compound; see the grades guide. Verify the specific lot's UL Yellow Card with the supplier on regulated installations.
ANSI Z87.1 — Eye and Face Protection
ANSI/ISEA Z87.1-2020 specifies minimum impact resistance, thickness, and abrasion resistance for safety eyewear lenses and face shields. Polycarbonate meets Z87.1 at 2mm (0.079") for lenses when tested to the high-impact requirement. For face shields (face and neck area), minimum thickness is typically 0.040" for high-impact compliance, with AR-coated grades required to meet the optical clarity and abrasion retention provisions.
UL 752 — Bullet-Resistant Materials
UL 752 is the standard for bullet-resistant glazing units. Polycarbonate assemblies are tested as complete units (frame + glazing + interlayer), not as bare sheet. Thicknesses shown are typical for monolithic or laminated PC to achieve each level:
| UL 752 Level | Caliber | Typical Assembly |
|---|---|---|
| Level 1 | 9mm FMJ (3 shots) | ~1.25" PC monolithic or laminate |
| Level 2 | .357 Magnum (3 shots) | ~1.50" PC laminate |
| Level 3 | .44 Magnum (3 shots) | ~1.75" PC laminate |
| Level 4 | .30 Cal Rifle (1 shot) | ~2.50" PC/glass/PU composite |
| Level 8 | 7.62mm AP (5 shots) | 3.5"+ multi-layer composite |
UL 752 certification applies to the complete glazing assembly — frame, glazing, interlayer, and sealant. Do not use bare sheet thickness as a proxy for level compliance.
NSF/ANSI 61 — Potable Water
Specific PC grades certified under NSF/ANSI 61 are acceptable for contact with potable water in plumbing components and water treatment equipment. See the polycarbonate FDA and food-grade guide for details.
Flatness and Optical Tolerances
- Bow/warp: max 0.5% per linear foot per ASTM D3935; thick sheet (≥0.375") runs flatter
- Haze: < 1% for Grade 1 clear (ASTM D1003)
- Light transmission: ≥ 85% Grade 1; 88% typical for clear
- Yellowness Index: < 1 for clear GP grades (ASTM E313)
Order Polycarbonate to Specification
Order polycarbonate cut to your specifications
Request a Quote →Federal Materials stocks standard slab sizes and offers precision cut-to-size for both sheet and rod. Specify thickness, width, length, grade (GP, UV-stabilized, AR-coated), and any applicable certification requirement (UL 94 V-2, NSF, ANSI Z87.1) when requesting a quote.
For fabrication guidance on machining, bending, and forming polycarbonate to specification, see the polycarbonate machining guide. For questions on comparing PC specifications against acrylic or PETG, the comparisons index links to side-by-side pages for each alternative material.
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