General Electric Plastics Guide Polycarbonate

Lexan polycarbonate is an
amorphous engineering
thermoplastic which is characterized
by high levels of mechanical, optical,
electrical and thermal properties.
The Lexan portfolio provides broad
design versatility through its wide
range of viscosities and product
options. These options include
halogen-free flame retardancy, impact
modification, glass-reinforcement,
optical quality and compliance with
stringent FDA and USP requirements.

The key properties which are
inherent in Lexan resin include:

High impact resistance over a wide
range of temperatures

Glass clear transparency

Wide range of colours

High gloss, quality surface finish

Excellent optical clarity

Excellent heat resistance: almost all
grades pass 125°C ball pressure test

Inherent limited flame retardancy:
all grades pass 850°C glow wire test
at 1.0 mm

Lexan resins are tailor-made for a
range of conversion processes
including injection moulding,
extrusion, blow moulding and foam
processing. High flow grades have
been developed which are ideally
suited to thin wall, long flow length
applications.

After their first application life, Lexan
resins can be reground and reused.
As is characteristic of an engineering
thermoplastic, Lexan resins retain a
high residual value and, in many
cases, they can be recycled into
similar applications within the same
industry. Alternatively, they can be
cascaded down for reuse in less
demanding applications.

I n t r o d u c t i o n

Lexan

Polycarbonate Resins

Lexan

Injection moulding

Extrusion

Structural foam

Unreinforced Multi Purpose

Unreinforced Lighting

Flame Retarded CSTB M2

Blowing Agent

Electrical

With its broad portfolio of flame
retarded and non-flame retarded
grades, both unreinforced and glass
reinforced, Lexan resin is found in
a wide range of electrical products.
These include meter and fuse box
housings, domestic switches, plugs
and sockets, switchgear, relays and
connectors.

Lexan resin’s key properties for the
electrotechnical industry include its:

Halogen-free* flame retarded system,
with most grades passing the Glow
Wire Test at 850°C

Excellent thermal properties with all
grades passing the Ball Pressure Test
at 125°C

Quality surface finish, high gloss or
textured, in a wide range of colours

High impact resistance

Good resistance to tracking and
arcing (CTI >175 volts)

Constant electrical properties in
aggressive environments

Excellent processibility

Compatibility with lasermarking
process

In addition, Lexan 3412R offers a
V0 flammability rating at wall
thicknesses of 0.8 mm according
to UL94 to meet the most critical
performance requirements of thin
walled connectors. Lexan 900 series
is specified for applications where
extremely low smoke evolution is a
requirement.

in accordance with

DIN VDE472 part 815

Lighting

Lexan resin is well-established in
the lighting industry, providing
manufacturers with lightweight,
quality parts, fast cycle times through
consistent processibility and
unlimited opportunities for design
integration and intricate, snap-fit
assembly.
Typical applications include linear
fluorescent luminaires, street lamps,
traffic lights, spotlights, reflectors,
lamp holders, emergency lights,
explosion-proof lights, conduits,
electrical supply track systems and
diffusers where Lexan resin features:

Outstanding impact resistance over
a wide range of temperatures, from
sub-zero to +125°C

Excellent optical properties

High heat resistance, with an HDT
under load of 133°C

Excellent dimensional stability and
low uniform shrinkage

Good resistance to tracking and
arcing (CTI >175 volts)

Good UV stability

Inherent corrosion resistance and
long-term weatherability; scratch and
chemical resistance can be further
increased through the application of
a GE Silicones’ hardcoat

Wide range of transparent and
opaque colours

M a r k e t s

Electrical

Lighting

Telecommunications

Optical

Automotive lighting

Appliances

Packaging

Table- and kitchen-ware

Medical

Optical disc storage

Extrusion

Telecommunications

Lexan resin is the material of choice
for a range of indoor and outdoor
telecommunications enclosures,
including power supply connection
boxes and base-stations, where it
features:

High temperature resistance

Good impact strength

Good dimensional stability

Good UV stability

Halogen-free* flame retarded

Quality aesthetics

Lexan structural foam grades are
an ideal choice for structural
components where load-bearing
capability at elevated temperatures
is a key requirement. They are an
excellent alternative to metal or
other plastics for the efficient
production of large parts such
as outdoor distribution cabinets.
Here they provide important weight
savings through an inherently high
stiffness to weight ratio. Furthermore,
for optimum UV protection, parts
can be easily painted.

in accordance with

DIN VDE472 part 815

Optical

The family of Lexan optical quality
(OQ) resins has been specifically
developed for the optical industry.
The range includes high impact
grades for safety goggles, optical
quality clean-room grades for
corrective lenses and grades offering
maximum UV screening up to
400 nm for sunglasses and ski visors.

Lexan OQ resins pass internationally
recognized industry standards
offering a tailor-made property
portfolio which includes:

‘Water white’ clarity, achieved
through proprietary technology

Light transmission >88%

Built-in UV screen

High impact resistance across
temperatures ranging from
sub-zero to +125°C

High temperature resistance allowing
the application of various anti-scratch
coatings

Excellent dimensional stability and
low water absorption

High refractive index of 1.586 which
allows the production of lenses which
are up to 20% thinner than with
traditional materials

Low specific gravity compared to
traditional materials, producing
lighter lenses

Fast, cost-efficient injection moulding
cycles and a high degree of precision

Unlimited design freedom to create
two-and three-dimensional shapes

L e x a n P r o f i l e 2 M a r k e t s

Automotive lighting

Tough, lightweight Lexan LS resins
have been specifically developed for
headlamp lenses. Their unlimited
design flexibility and moulding
precision allows them to be formed
into complex shapes. Accurate
refraction planes provide exceptional
lighting performance, while
integrated fixings reduce
components and simplify assembly.
GE Silicones’ proprietary hardcoating
system provides optimum abrasion
resistance throughout the life of
the vehicle. As well as providing
manufacturers with consistent high
quality, Lexan resin can considerably
enhance productivity when the lens
is designed as part of a total lighting
system.

Lexan resin is also ideally suited to
the production of bezels which can
be metallized without the use of a
primer or lacquer. Manufacturers can
produce lightweight, state-of-the-art
parts with optimum cost-efficiency
thanks to Lexan resin’s inherent
design freedom and opportunities
for thin wall moulding and part
integration.

Appliances

Lexan resin is widely used in the
appliances industry for products such
as food mixers and processors, steam
iron water tanks and oven control
panels where its key features are its:

Exceptional practical impact
resistance

High heat resistance

Consistent processibility

High quality glass-like transparency
and gloss

Wide range of colours, with many
colours having transparent and
translucent as well as opaque versions

Inherent design freedom

For products like vacuum cleaner
motor end-caps, diffusers and brush
holders which require superior
rigidity and stiffness, glass-filled
Lexan polycarbonate offers high
modulus and high impact
performance, combined with ease
of assembly through unlimited
opportunities for design integration
and intricate, snap-fit assembly.

Following market trends for cost
reduction and product
differentiation, GE Plastics has
recently developed in partnership
with industry two innovative
appliance concepts which
demonstrate the unique advantages
of using Lexan polycarbonate. The
first is an oven door which features:

Cool-to-the-touch properties which
are due to the thermal conductivity
of Lexan resin being down to four
times less than that of glass

Cost-efficient product differentiation
through in-mould finishing which
involves placing a pre-printed,
vacuum formed Lexan film in the
door mould prior to injection
moulding

Inherent design freedom for cost-
efficient styling advantages to achieve,
for example, fashionable, rounded
shapes

Enhanced productivity through snap-
fit assembly

The second design concept is an
injection moulded, circular dryer
door. This single component
comprises an integrated locking
mechanism, frame, bull’s-eye window
and hinge. Cost-effective variations in
colour and decoration can be easily
achieved through in-mould finishing.

Packaging

The use of Lexan polycarbonate
returnable milk bottles is well-
established as a cost-effective, user-
and environment-friendly alternative
to glass and to one-way disposable
cartons and plastic bottles. Popular
with dairy, distributor and consumer
alike, the Lexan resin bottle can be
washed and refilled up to 50 times
while maintaining excellent taste
neutrality and its characteristic high
quality, glass-like transparency.

The key advantages of Lexan resin
in milk packaging are its:

Glass-like transparency and gloss

Excellent taste and aroma protection
in compliance with FDA and
European food contact regulations

High impact properties and practical
toughness for safe handling

High temperature resistance to
withstand repeated wash cycles

Light weight for ease of handling and
cost-effective transportation

Compatibility with existing materials
handling systems

Wide design flexibility for a diversity
of bottle shapes, sizes and features

Wide range of colours

Recyclability for use in other non-
food applications

Lexan resin is also used in the
production of water bottles where,
as with milk packaging, its key
properties are its taste neutrality,
high temperature resistance for
cleanability and its long life

expectancy compared with glass
products. Tailor-made branched
resin, Lexan PKG1643, offers
moulders the ability to produce
a high quality water bottle with a
more uniform wall thickness.

In food packaging applications,
Lexan resin can also be used as a top
layer in the coextrusion of multi-layer
film where it provides:

High mechanical strength

High heat resistance

High gloss

Good slip, anti-blocking and film
winding properties

L e x a n P r o f i l e 2 M a r k e t s

Table- and kitchen-ware

Lexan polycarbonate table- and
kitchen-ware is well-established in
the domestic, commercial and
institutional catering markets.
In addition to full compliance with
FDA and European food legislation,
Lexan resin offers these markets the
following key benefits:

Inherent high impact strength and
practical toughness for products
which are virtually unbreakable

Excellent thermal and dimensional
stability allowing repeated washing at
high temperatures and reheating of
foodstuffs using hot air, water bath
or microwave oven

Medical

Lexan polycarbonate meets the
requirements of the FDA and USP
Chapter XXII Class V1 for use in the
medical industry. It is widely used for
a variety of medical devices and
equipment including trocar tubes,
syringes, dialysis apparatus, blood
filters and blood oxygenators.
Products can be sterilized by all three
commonly used methods: gamma
radiation, EtO gas and steam
(autoclave). Superior colour stability
and resistance to yellowing following
gamma or EtO sterilisation is a key
feature of tailor-made Lexan GR
grades.

The key properties of Lexan resin
in medical applications are its:

High impact resistance

High temperature resistance

Glass-like clarity

Good processibility

Design versatility

L e x a n P r o f i l e 2 M a r k e t s

Optical disc storage

With dedicated manufacturing
facilities in the Netherlands, USA
and Japan, GE Plastics is the only
global supplier of polycarbonate
resins to optical disc market. Tailor-
made Lexan Optical Quality (OQ)
resins are renowned for their
excellent product consistency, both
in terms of purity and processibility.
Due to their low molecular weight,
these materials have an ultra-high
melt flow rate which allows the
moulding of discs with very low
birefringence and excellent pit and
track replication.

Working closely with its industry
partners, GE Plastics continues to
push forward with state-of-the-art
materials and process technology
which will revolutionize the
production of new optical media.
Included in recent developments is
a further improved flow Lexan OQ
resin which features lower
birefringence, enhanced surface
replication and superior flatness
for the DVD format.

Extrusion

Specially developed UV-stable Lexan
extrusion resins can be readily
extruded on conventional
equipment. The range includes both
linear and branched polymers for
solid, multi- and twin-wall sheet
extrusion.

In general, Lexan extrusion grades
offer:

Consistent ease of processing

Excellent surface finish and
transparency

Outstanding impact performance

In addition, glass clear UV cap-layer
materials have been specifically
developed to improve the UV
performance of extruded solid, multi-
and twin-wall polycarbonate sheet.
For typical applications such as
roofing sheets, these unique materials
meet critical industry standards for
outdoor weatherability, while
providing enhanced productivity.

L e x a n P r o f i l e 2 M a r k e t s

Lexan 100 Series
(Unreinforced, Non-Flame Retarded)

Wide viscosity range:
120 series: low viscosity
140 series: low to medium viscosity
160 series: medium viscosity
100 series: high viscosity
130 series: very high viscosity

R grades have easy release
characteristics

1x3R grades are UV stabilized

1x4R grades comply with various
food contact regulations

All grades have wide colour
availability

Lexan HF Series (High Flow)

Formulated using a unique
chemical modification of the base
polycarbonate polymer

Very low viscosity levels with minimal
reduction in inherent properties

Ideally suited to thin wall, high flow
length applications

All grades have easy release
characteristics

HF1130R is UV stabilized

HF1140R is suitable for food and
medical applications

see page 11

see page 9

see page 13

see page 15

Lexan

Injection moulding

Extrusion

Structural foam

non-flame retarded 1xy series

flame retarded UL94V2 2xy series

flame retarded UL94V0

flame retarded CSTB M2

lens system · optimal clarity

reduced property profile

Unreinforced Multi purpose

Unreinforced Lighting

Flame Retarded CSTB M2

Blowing Agent

P r o d u c t S e l e c t i o n

L e x a n P r o f i l e 3 P r o d u c t S e l e c t i o n

see page 13

see page 15

Unreinforced Lighting

flame retarded UL94V2 2xy series

flame retarded UL94V0

flame retarded CSTB M2

Unreinforced Optical

Glass Reinforced

Specialties

FLOW

144R

142°C

•

25 (10) kJ/m

•

2300 MPa

HB/1.14 mm

•

12 cm

/10min

124R

141°C

•

12 (10) kJ/m

•

2300 MPa

HB/1.14 mm

•

21 cm

/10min

123R

141°C

•

12 (10) kJ/m

•

2300 MPa

HB/1.47 mm

•

21 cm

/10min

ML3729

140°C

•

12 (4) kJ/m

•

2300 MPa

V2/0.80 mm

•

40 cm

/10min

HF1110R

140°C

•

12 (10) kJ/m

•

2300 MPa

V2/1.09 mm

•

26 cm

/10min

HF1130R

140°C

•

12 (10) kJ/m

•

2300 MPa

V2/1.60 mm

•

26 cm

/10min

HF1140R

140°C

•

12 (10) kJ/m

•

2300 MPa

V2/1.09 mm

•

26 cm

/10min

121 / 121R

141°C

•

12 (10) kJ/m

•

2300 MPa

HB/1.14 mm

•

21 cm

/10min

143 / 143R

142°C

•

25 (10) kJ/m

•

2300 MPa

HB/1.47 mm

•

12 cm

/10min

164R

145°C

•

60 (10) kJ/m

•

2300 MPa

HB/1.14 mm

•

9 cm

/10min

104R

145°C

•

65 (10) kJ/m

•

2300 MPa

HB/1.14 mm

•

6 cm

/10min

134R

145°C

•

65 (10) kJ/m

•

2300 MPa

V2/1.60 mm

•

3 cm

/10min

141 / 141R

142°C

•

25 (10) kJ/m

•

2300 MPa

HB/1.14 mm

•

12 cm

/10min

163R

145°C

•

60 (10) kJ/m

•

2300 MPa

HB/1.47 mm

•

9 cm

/10min

161R

145°C

•

60 (10) kJ/m

•

2300 MPa

HB/1.14 mm

•

9 cm

/10min

103/ 103R

145°C

•

65 (10) kJ/m

•

2300 MPa

HB/1.47 mm

•

6 cm

/10min

101 / 101R

145°C

•

65 (10) kJ/m

•

2300 MPa

HB/1.14 mm

•

6 cm

/10min

food, medical & toys

UV stability

food, medical & toys

UV stability

food, medical & toys

UV stability

food, medical & toys

UV stability

Lexan 200 Series
(Unreinforced, Flame Retarded)

Differing levels of viscosity:
220 series: low viscosity
240 series: low to medium viscosity
260 series: medium viscosity
200 series: high viscosity

R grades have easy release
characteristics

2x3R grades are UV stabilized

All grades have wide colour
availability

All grades are rated UL94 V2
at measured thickness

Lexan 900 Series
(Unreinforced, Flame Retarded)

Transparent and opaque UL94 flame
class rated grades

Available in different melt viscosities

All products have easy release
characteristics

9x3 and 9x3A grades are UV
stabilized

9xy series are available only in opaque
colours

9xyA series are available in opaque
and transparent colours

L e x a n P r o f i l e 3 P r o d u c t S e l e c t i o n

Grade:

‘R’ grades show ‘easy release’

Heat:

Vicat B/120 in °C (ISO 306)

Impact:

Izod Notched at 23 (-30)°C
in kJ/m

(ISO 180/1A)

Modulus:

Flexural in MPa (ISO 178)

Flammability:

Flame class at mm thickness
(UL94)

Flow:

MVR at 300°C/1.2kg
in cm

/10min (ISO1133)

Flow*:

MVR at 250°C/1.2kg
in cm

/10min (ISO1133)

n.t.: not tested · NB: not broken
‘all colours’ means ‘available in transparent,
translucent and opaque colours, unless
otherwise indicated’

GRADE

Heat

•

Impact

•

Modulus

Flammability

•

Flow

L e x a n P r o f i l e 3 P r o d u c t S e l e c t i o n

FLOW

223R

141°C

•

12 (10) kJ/m

•

2300 MPa

V2/1.47 mm

•

21 cm

/10min

243R

142°C

•

25 (10) kJ/m

•

2300 MPa

V2/1.47 mm

•

12 cm

/10min

263R

145°C

•

60 (10) kJ/m

•

2300 MPa

V2/1.47 mm

•

9 cm

/10min

203R

145°C

•

65 (10) kJ/m

•

2300 MPa

V2/1.47 mm

•

6 cm

/10min

920

141°C

•

9 (7) kJ/m

•

2300 MPa

V0/1.04 mm

•

21 cm

/10min

923

141°C

•

9 (7) kJ/m

•

2300 MPa

V0/1.00 mm

•

21 cm

/10min

940

142°C

•

12 (11) kJ/m

•

2300 MPa

V0/1.04 mm

•

9.5 cm

/10min

943

142°C

•

12 (11) kJ/m

•

2300 MPa

V0/1.00 mm

•

9.5 cm

/10min

950

145°C

•

15 (n.t.) kJ/m

•

2300 MPa

V0/1.04 mm

•

6.5 cm

/10min

920A

142°C

•

10 (nt) kJ/m

•

2300 MPa

V0/3.05 mm

•

12 cm

/10min

923A

142°C

•

10 (nt) kJ/m

•

2300 MPa

V0/3.20 mm

•

12 cm

/10min

940A

142°C

•

12 (10) kJ/m

•

2300 MPa

V0/3.05 mm

•

9.5 cm

/10min

943A

142°C

•

12 (10) kJ/m

•

2300 MPa

V0/3.20 mm

•

9.5 cm

/10min

2014R

145°C

•

8 (8) kJ/m

•

2300 MPa

V2/1.47 mm

•

8.5 cm

/10min

2034

145°C

•

8 (8) kJ/m

•

2300 MPa

V2/1.50 - V0/2.50 mm

•

8.5 cm

/10min

221R

141°C

•

12 (10) kJ/m

•

2300 MPa

V2/1.14 mm

•

21 cm

/10min

241R

142°C

•

25 (10) kJ/m

•

2300 MPa

V2/1.14 mm

•

12 cm

/10min

261R

145°C

•

60 (10) kJ/m

•

2300 MPa

V2/1.14 mm

•

9 cm

/10min

201R

145°C

•

65 (10) kJ/m

•

2300 MPa

V2/1.14 mm

•

6 cm

/10min

UV stability

easy release

non-flame retarded 1xy series

Unreinforced Lighting

Unreinforced Optical

Glass Reinforced

Specialties

Lexan LS Series (Lens System)

Specifically developed for parts
requiring high optical quality,
i.e. clarity and light transmission

Range of viscosity levels

Lexan LS2 meets all global
automotive OEM specifications in
the US, Europe and Asia, including
SAE 576, the global standard for
outdoor weathering

All grades have easy release
characteristics

Lexan Optical Series

Tailor-made Lexan OQ (Optical
Quality) resins satisfy stringent purity
requirements of optical data storage
discs

Grade with ultra-high melt flow rate
and lower birefringence for high
density DVD market

Grades for LCD’s available with
different melt viscosities

Special grades for ophthalmic and
safety lenses with superior properties
to acrylic and glass

Range of transparent colours
complemented by opaque white for
a very high degree of reflectivity

Lexan Glass Reinforced, Flame
Retarded Series

UL94 flame class rated grades

Range of multi purpose, standard
length glass fibre reinforced grades,
complemented by a short glass fibre
grade with superior dimensional
stability

10% to 40% glass reinforced grades

Excellent rigidity, high heat resistance
and superior impact strength
compared with other filled resins

Highly stable mechanical and
electrical properties

Lower coefficient of thermal
expansion and reduced mould
shrinkage

Availability in different viscosity levels

R grades have easy release
characteristics

L e x a n P r o f i l e 3 P r o d u c t S e l e c t i o n

Grade:

‘R’ grades show ‘easy release’

Heat:

Vicat B/120 in °C (ISO 306)

Impact:

Izod Notched at 23 (-30)°C
in kJ/m

(ISO 180/1A)

Modulus:

Flexural in MPa (ISO 178)

Flammability:

Flame class at mm thickness
(UL94)

Flow:

MVR at 300°C/1.2kg
in cm

/10min (ISO1133)

Flow*:

MVR at 250°C/1.2kg
in cm

/10min (ISO1133)

n.t.: not tested · NB: not broken
‘all colours’ means ‘available in transparent,
translucent and opaque colours, unless
otherwise indicated’

GRADE

Heat

•

Impact

•

Modulus

Flammability

•

Flow

L e x a n P r o f i l e 3 P r o d u c t S e l e c t i o n

FLOW

LS1

141°C

•

12 (10) kJ/m

•

2300 MPa

HB/1.47 mm

•

21 cm

/10min

LS2

142°C

•

25 (11) kJ/m

•

2300 MPa

HB/1.47 mm

•

12 cm

/10min

LS3

145°C

•

60 (10) kJ/m

•

2300 MPa

HB/1.47 mm

•

6 cm

/10min

OQ1020LN

142°C

•

10 (4) kJ/m

•

2300 MPa

n.t.

•

11*cm

/10min

OQ4320

142°C

•

65 (11) kJ/m

•

2300 MPa

n.t.

•

12 cm

/10min

ML3042

145°C

•

50 (15) kJ/m

•

2500 MPa

n.t.

•

6 cm

/10min

500R

143°C

•

8 (8) kJ/m

•

3400 MPa

V0/1.47 - 5VA/3.05 mm

•

8 cm

/10min

503R

143°C

•

8 (8) kJ/m

•

3400 MPa

V0/1.47 - 5VA/3.05 mm

•

8 cm

/10min

ML3019

142°C

•

n.t. (n.t.)

•

3400 MPa

V0/1.60 mm

•

8 cm

/10min

2814R

143°C

•

6 (6) kJ/m

•

3400 MPa

V0/1.47 mm

•

6 cm

/10min

ML3260

143°C

•

8 (8) kJ/m

•

4000 MPa

V1/1.60 mm

•

11 cm

/10min

1278R

143°C

•

8 (8) kJ/m

•

5000 MPa

V1/1.57 mm

•

12 cm

/10min

3412R

145°C

•

8 (6) kJ/m

•

5500 MPa

V0/0.80 mm

•

6 cm

/10min

3413R

145°C

•

8 (6) kJ/m

•

7000 MPa

V0/1.47 mm

•

5 cm

/10min

3414R

145°C

•

8 (6) kJ/m

•

8500 MPa

V0/1.50 mm

•

4 cm

/10min

ML3513

150°C

•

8 (8) kJ/m

•

4500 MPa

V0/1.50 mm

•

4 cm

/10min

Unreinforced Multi purpose

UV Stability

low knock-out strength

dimensional stability

· low warpage

CSTB M1

easy release

transparent colours

Lexan Specialties

The Lexan range of specialty
products can be divided into ‘Impact
Modified’, ‘Gamma Sterilizable’ and
‘Reduced Properties’.

Lexan resins with enhanced impact at
sub-zero temperatures are available in
high and low viscosity grades, offering
increased resistance to chemicals
such as paint systems

Lexan GR resins offer gamma
resistance for medical applications.
These tailor-made grades provide
excellent colour stability and
resistance to yellowing after gamma
radiation

Lexan resins with reduced properties
are available in both unreinforced
and glass reinforced grades for
applications with less critical impact
requirements

Lexan Extrusion and
Blow Moulding Series

Extrusion, injection blow moulding
and extrusion blow moulding grades

Linear and branched polymers

CSTB M2 rated material available

Tailor-made grades meet specific
requirements for UV stability,
hydrolytic stability and compliance
with food contact regulations

Lexan Structural Foam Moulding
Series

Stress-free mouldings particularly
suitable for large parts

High heat distortion, combined with
good flame retardancy and high
electrical resistivity

5% glass filled foam grades

Tailor-made low pressure chemical
blowing agent for standard and
increased process temperatures

L e x a n P r o f i l e 3 P r o d u c t S e l e c t i o n

Grade:

‘R’ grades show ‘easy release’

Heat:

Vicat B/120 in °C (ISO 306)

Impact:

Izod Notched at 23 (-30)°C
in kJ/m

(ISO 180/1A)

Modulus:

Flexural in MPa (ISO 178)

Flammability:

Flame class at mm thickness
(UL94)

Flow:

MVR at 300°C/1.2kg
in cm

/10min (ISO1133)

Flow*:

MVR at 250°C/1.2kg
in cm

/10min (ISO1133)

n.t.: not tested · NB: not broken
‘all colours’ means ‘available in transparent,
translucent and opaque colours, unless
otherwise indicated’

GRADE

Heat

•

Impact

•

Modulus

Flammability

•

Flow

L e x a n P r o f i l e 3 P r o d u c t S e l e c t i o n

ML3021A

146°C

•

60 (13) kJ/m

•

2300 MPa

HB/1.60 mm

•

4 cm

/10min

ML3403

148°C

•

65 (13) kJ/m

•

2300 MPa

n.t.

•

5 cm

/10min

154

143°C

•

60 (10) kJ/m

•

2300 MPa

n.t.

•

n.t.

PKG1643

143°C

•

60 (10) kJ/m

•

2300 MPa

n.t.

•

n.t.

ML3324

143°C

•

60 (10) kJ/m

•

2300 MPa

HB/1.50 mm

•

n.t.

ML3290

135°C

•

15 (10) kJ/m

•

2300 MPa

V0/2.00 mm

)

•

n.t.

2034E

148°C

•

8 (8) kJ/m

•

2300 MPa

n.t.

•

n.t.

FL900P

n.t.

•

n.t.

•

n.t.

•

10 cm

/10min

FLC95

ML3041

141°C

•

58 (17) kJ/m

•

2300 MPa

V2/1.00 mm

•

10 cm

/10min

ML3400

142°C

•

58 (50) kJ/m

•

2150 MPa

n.t.

•

8 cm

/10min

ML3459

140°C

•

65 (40) kJ/m

•

2150 MPa

n.t.

•

9 cm

/10min

GR1210

131°C

•

11 (8) kJ/m

•

2400 MPa

n.t.

•

14 cm

/10min

ML3562

138°C

•

15 (10) kJ/m

•

2100 MPa

V2/1.00 mm

•

24 cm

/10min

ML3286

n.t.

•

NB (20) kJ/m

•

4500 MPa

n.t.

•

12 cm

/10min

easy release
unreinforced

opaque colours

limited colours

transparent colours

limited colours

) UL rating V0/2.0 of ML3290 is only valid for clear colours

Unreinforced Multi purpose

Unreinforced Lighting

Unreinforced Optical

Glass Reinforced

)

values may differ with pigmented materials

)

only typical data for material selection purposes - not to be
used for part/tool design; for glass reinforced grades: values
may differ with glass fibre orientation

)

as recognized on UL yellow cards; UL recognition may differ with colour

)

values may differ with glass fibre orientation

)

these ratings are not intended to reflect hazards presented by this or
other material under actual fire conditions

L e x a n P r o f i l e 3 P r o d u c t S e l e c t i o n p a g e 1 6

Typical Properties

Typical values only.

Variations within normal tolerances are possible for various colours.

Test Method

ISO

DIN

ASTM

IEC*

VDE*

other*

Unit

Test Specimen

MPTS (multi-purpose test speci-

men) as defined in ISO 3167.

Smaller test specimens may be

machined from MPTS.

All dimensions in mm.

Mechanical

Tensile stress

at yield [at break]

at 50 mm/min

MPa

527

at break

at 5 mm/min

MPa

527

MPTS (150 x 20/10 x 4)

Tensile strain

at yield [at break]

at 50 mm/min

527

at break

at 5 mm/min

527

MPTS

Tensile modulus

at 1 mm/min

MPa

527

MPTS

Flexural stress

at yield [at break]

at 2 mm/min

MPa

178

80 x 10 x 4

Flexural modulus

at 2 mm/min

MPa

178

80 x 10 x 4

Hardness

Ball indentation

H 358/30

MPa

2039-1

50 x 50 x 4

Abrasion resistance

Taber, CS-17, 1 kg

per 1000 cycles

mg/1000 cy

GE*

Impact

Izod

notched

at +23°C [-30°C]

kJ/m

180-1A

unnotched

at +23°C [-30°C]

kJ/m

180-1U

80 x 10 x 4

Thermal

Vicat A/50

10N (method A)

at 50°C/h

°C

306

B/50

50N (method B)

at 50°C/h

°C

306

110 x 10 x 4

B/120

50N (method B)

at 120°C/h

°C

306

HDT/Ae 1.80 MPa

edgewise, span 120 mm

at 1.80 MPa

°C

75/Ae

/Be 0.45 Mpa

at 0.45 MPa

°C

75/Be

110 x 10 x 4

Ball pressure

passes at °C

°C

695-10-2

Relative Temperature Index

RTI

Electrical properties

°C

UL746B*

)

Mechanical properties with Impact

°C

UL746B*

Mechanical properties without Impact

°C

UL746B*

Thermal conductivity

W/m°C

52612

C177

Coefficient of Thermal Expansion

CTE

in flow direction

1/°C

53752

D696

)

Flammability

UL94 rating

flame class rating

at mm thickness

class at mm

UL94*

125 x 13, thickness as noted

)

Limited Oxygen Index

LOI

4589

D2863

150/80 x 10 x 4

)

Glow wire

passed at °C

at mm thickness

°C at mm

695-2-1*

Electrical

Dielectric strength

in oil

at 0.8 mm / 1.6 mm / 3.2 mm

kV/mm

243*

D149

Surface resistivity

Ohm

93*

D257

Volume resistivity

Ohm·cm

93*

D257

Relative permittivity

or Dielectric constant

at 50 Hz

—

250*

D150

at 1 MHz

—

250*

D150

Dissipation factor

or Loss tangent

at 50 Hz

—

250*

D150

at 1 MHz

—

250*

D150

Comparative Tracking Index

CTI

50 drops [M: wetting agent]

112/3rd*

D3638

)

Physical

Density

g/cm

1183

D792

Water absorption

at saturation

at 23°C, in water

53495

D570

Mould shrinkage

in flow direction

527

D955

)

Optical

Light transmission

D1003

Haze

D1003

Refractive index

—

489

Rheological

Melt Volume Rate

MVR

at 300°C / 1.20 kg

/10 min

1133

53735

granules

L e x a n P r o f i l e 3 P r o d u c t S e l e c t i o n p a g e 1 7

NB : not broken · – : not relevant · n.t.: not tested

ML3729

60 (55)

–

6 (70)

–

2300

85 (–)

2300

12 (4)

NB (NB)

145

139

140

121

133

125

n.t.

0.20

7·10

-5

V2/0.8*)

850/1.0

35 / 27 / 17

>10

2.7

2.6

0.001

0.01

n.t.

1.20

0.35

0.50 - 0.70

88 - 90

< 0.8

1.586

HF1110R

63 (50)

–

6 (70)

–

2350

90 (–)

2300

12 (10)

NB (NB)

145

139

140

121

133

125

115

125

0.20

7·10

-5

V2/1.09

850/1.0

35 / 27 / 17

>10

2.7

2.6

0.001

0.01

250

1.20

0.35

0.50 - 0.70

88 - 90

< 0.8

1.586

HF1130R

63 (50)

–

6 (70)

–

2350

90 (–)

2300

12 (10)

NB (NB)

145

139

140

121

133

125

n.t.

0.20

7·10

-5

V2/1.60

850/1.0

n.t./n.t./ 17

>10

3.0

2.9

0.001

0.01

n.t.

1.20

0.35

0.50 - 0.70

88 - 90

< 0.8

1.586

HF1140R

63 (50)

–

6 (70)

–

2350

90 (–)

2300

12 (10)

NB (NB)

145

139

140

121

133

125

115

125

0.20

7·10

-5

V2/1.09

850/1.0

n.t./n.t./ 17

>10

3.0

2.9

0.001

0.01

n.t.

1.20

0.35

0.50 - 0.70

88 - 90

< 0.8

1.586

121/121R

63 (65)

–

6 (100)

–

2350

90 (–)

2300

12 (10)

NB (NB)

–

140

141

122

133

125

130

125

0.20

7·10

-5

HB/1.14

)

850/1.0

n.t./n.t./ 17

)

>10

3.0

)

2.9

)

0.001

0.01

n.t.

1.20

0.35

0.50 - 0.70

88 - 90

< 0.8

1.586

123R

63 (65)

–

6 (100)

–

2350

90 (–)

2300

12 (10)

NB (NB)

–

140

141

122

133

125

130

125

0.20

7·10

-5

HB/1.47

850/1.0

n.t./n.t./ 17

>10

3.0

2.9

0.001

0.01

n.t.

1.20

0.35

0.50 - 0.70

88 - 90

< 0.8

1.586

124R

63 (65)

–

6 (100)

–

2350

90 (–)

2300

12 (10)

NB (NB)

–

140

141

122

133

125

130

125

0.20

7·10

-5

HB/1.14

850/1.0

n.t./n.t./ 17

>10

3.0

2.9

0.001

0.01

n.t.

1.20

0.35

0.50 - 0.70

88 - 90

< 0.8

1.586

141/141R

63 (70)

–

6 (110)

–

2350

90 (–)

2300

25 (10)

NB (NB)

153

141

142

125

136

125

130

125

0.20

7·10

-5

HB/1.14

)

850/1.0

n.t./n.t./ 17

)

>10

3.0

)

2.9

)

0.001

0.01

250

1.20

0.35

0.50 - 0.70

88 - 90

< 0.8

1.586

143/143R

63 (70)

–

6 (110)

–

2350

90 (–)

2300

25 (10)

NB (NB)

153

141

142

125

136

125

130

125

0.20

7·10

-5

HB/1.47

850/1.0

n.t./n.t./ 17

>10

3.0

2.9

0.001

0.01

250

1.20

0.35

0.50 - 0.70

88 - 90

< 0.8

1.586

144R

63 (70)

–

6 (110)

–

2350

90 (–)

2300

25 (10)

NB (NB)

153

141

142

125

136

125

130

125

0.20

7·10

-5

HB/1.14

850/1.0

n.t./n.t./ 17

>10

3.0

2.9

0.001

0.01

n.t.

1.20

0.35

0.50 - 0.70

88 - 90

< 0.8

1.586

Unreinforced Multi purpose

lowest

viscosity

very low viscosity

low viscosity

low to medium viscosity

Injection moulding

non-flame retarded 1xy series

page 21

page 18

page 19

UL94 in-house tested

)

LOI of 121R, 141R and 101R is 28

)

1141R and 101R is 35 / 27 / 17

)

Relative permittivity at 50 Hz of

121R, 141R and 101R is 2.7

)

Relative permittivity at 1 MHz of 121R, 141R and 101R is 2.6

)

MVR of OQ1020LN at 250°C/1.20 kg

)

MVR of 154, PKG1643 and 2034E at 80°C/3.80 kg

)

MVR of ML3324 and ML3290 at 300°C/2.16 kg

L e x a n P r o f i l e 3 P r o d u c t S e l e c t i o n p a g e 1 8

Typical Properties

Typical values only.

Not to be used for

specification purposes.

NB : not broken · – : not relevant · n.t.: not tested

Mechanical

Tens. stress

y (b)

Tens. strain

y (b)

Tens. modulus

Flex. stress

y (b)

Flex. modulus

Hardness

Ball

Abrasion

Taber

Impact

Izod notch.

23° (-30°) C

unnotch.

23° (-30°) C

Thermal

Vicat A/50

B/50

B/120

HDT / Ae 1.80 MPa

/ Be 0.45 Mpa

Ball Pressure

RTI

Electrical

Mech. with Impact

without Impact

Thermal conductivity

CTE flow

Flammability

UL94

LOI

Glow wire

Electrical

Diel. str. oil 0.8 / 1.6 / 3.2 mm

Surface resistivity

Volume resistivity

Rel. permitt.

50 Hz

1 MHz

Dissipation f. 50 Hz

1 MHz

CTI

Physical

Density

Water abs.

23°C

Mould shrink. flow

Optical

Light transmission

Haze

Refractive index

Rheological

MVR

Unit

MPa

mg/1000 cy

kJ/m

°C

W/m°C

1/°C

class at mm

°C at mm

kV/mm

Ohm

Ohm·cm

—

g/cm

—

/10 min

Unreinforced Multi purpose

medium viscosity

high viscosity

highest

viscosity

Injection moulding

non-flame retarded 1xy series

page 17

page 21

page 19

UL94 in-house tested

)

LOI of 121R, 141R and 101R is 28

)

1141R and 101R is 35 / 27 / 17

)

Relative permittivity at 50 Hz of

121R, 141R and 101R is 2.7

161R

63 (70)

–

6 (120)

–

2350

90 (–)

2300

60 (10)

NB (NB)

–

143

145

127

138

125

130

125

0.20

7·10

-5

HB/1.14

850/1.0

35 / 27 / 17

>10

2.7

2.6

0.001

0.01

225

1.20

0.35

0.50 - 0.70

88 - 90

< 0.8

1.586

9.5

163R

63 (70)

–

6 (120)

–

2350

90 (–)

2300

60 (10)

NB (NB)

–

143

145

127

138

125

130

125

0.20

7·10

-5

HB/1.47

850/1.0

n.t./n.t./ 17

>10

3.0

2.9

0.001

0.01

n.t.

1.20

0.35

0.50 - 0.70

88 - 90

< 0.8

1.586

9.5

164R

63 (70)

–

6 (120)

–

2350

90 (–)

2300

60 (10)

NB (NB)

–

143

145

127

138

125

130

125

0.20

7·10

-5

HB/1.14

850/1.0

n.t./n.t./ 17

>10

3.0

2.9

0.001

0.01

n.t.

1.20

0.35

0.50 - 0.70

88 - 90

< 0.8

1.586

9.5

101/101R

63 (70)

–

6 (120)

–

2350

90 (–)

2300

65 (10)

NB (NB)

–

144

145

127

138

125

130

125

0.20

7·10

-5

HB/1.14

)

850/1.0

n.t./n.t./ 17

)

>10

3.0

)

2.9

)

0.001

0.01

n.t.

1.20

0.35

0.50 - 0.70

88 - 90

< 0.8

1.586

103/103R

63 (70)

–

6 (120)

–

2350

90 (–)

2300

65 (10)

NB (NB)

–

144

145

127

138

125

130

125

0.20

7·10

-5

HB/1.47

850/1.0

n.t./n.t./ 17

>10

3.0

2.9

0.001

0.01

n.t.

1.20

0.35

0.50 - 0.70

88 - 90

< 0.8

1.586

104R

63 (70)

–

6 (120)

–

2350

90 (–)

2300

65 (10)

NB (NB)

–

144

145

127

138

125

130

125

0.20

7·10

-5

HB/1.14

850/1.0

n.t./n.t./ 17

>10

3.0

2.9

0.001

0.01

n.t.

1.20

0.35

0.50 - 0.70

88 - 90

< 0.8

1.586

134R

63 (70)

–

6 (120)

–

2400

90 (–)

2300

65 (10)

NB (NB)

–

144

145

131

140

125

n.t.

0.20

7·10

-5

V2/1.60*)

850/1.0

n.t./n.t./ 16

>10

3.0

2.9

0.001

0.01

n.t.

1.20

0.35

0.50 - 0.70

88 - 90

< 0.8

1.586

)

Relative permittivity at 1 MHz of 121R, 141R and 101R is 2.6

)

MVR of OQ1020LN at 250°C/1.20 kg

)

MVR of 154, PKG1643 and 2034E at 80°C/3.80 kg

)

MVR of ML3324 and ML3290 at 300°C/2.16 kg

L e x a n P r o f i l e 3 P r o d u c t S e l e c t i o n p a g e 1 9

Typical Properties

Typical values only.

Not to be used for

specification purposes.

NB : not broken · – : not relevant · n.t.: not tested

Mechanical

Tens. stress

y (b)

Tens. strain

y (b)

Tens. modulus

Flex. stress

y (b)

Flex. modulus

Hardness

Ball

Abrasion

Taber

Impact

Izod notch.

23° (-30°) C

unnotch.

23° (-30°) C

Thermal

Vicat A/50

B/50

B/120

HDT / Ae 1.80 MPa

/ Be 0.45 Mpa

Ball Pressure

RTI

Electrical

Mech. with Impact

without Impact

Thermal conductivity

CTE flow

Flammability

UL94

LOI

Glow wire

Electrical

Diel. str. oil 0.8 / 1.6 / 3.2 mm

Surface resistivity

Volume resistivity

Rel. permitt.

50 Hz

1 MHz

Dissipation f. 50 Hz

1 MHz

CTI

Physical

Density

Water abs.

23°C

Mould shrink. flow

Optical

Light transmission

Haze

Refractive index

Rheological

MVR

Unreinforced Multi purpose

low

viscosity

low to medium

viscosity

medium

viscosity

high

viscosity

Injection moulding

flame retarded 2xy series

221R

63 (65)

–

6 (100)

–

2350

90 (–)

2300

12 (10)

NB (NB)

–

140

141

122

133

125

130

125

0.20

7·10

-5

V2/1.14

850/1.0

35 / 27 / 17

>10

2.7

2.6

0.001

0.01

n.t.

1.20

0.35

0.50 - 0.70

88 - 90

< 0.8

1.586

223R

63 (65)

–

6 (100)

–

2350

90 (–)

2300

12 (10)

NB (NB)

–

140

141

122

133

125

130

125

0.20

7·10

-5

V2/1.47

850/1.0

n.t./n.t./ 17

>10

3.0

2.9

0.001

0.01

n.t.

1.20

0.35

0.50 - 0.70

88 - 90

< 0.8

1.586

241R

63 (70)

–

6 (110)

–

2350

90 (–)

2300

25 (10)

NB (NB)

153

141

142

125

136

125

130

125

0.20

7·10

-5

V2/1.14

850/1.0

35 / 27 / 17

>10

2.7

2.6

0.001

0.01

n.t.

1.20

0.35

0.50 - 0.70

88 - 90

< 0.8

1.586

243R

63 (70)

–

6 (110)

–

2350

90 (–)

2300

25 (10)

NB (NB)

153

141

142

125

136

125

130

125

0.20

7·10

-5

V2/1.47

850/1.0

n.t./n.t./ 17

>10

3.0

2.9

0.001

0.01

n.t.

1.20

0.35

0.50 - 0.70

88 - 90

< 0.8

1.586

261R

63 (70)

–

6 (120)

–

2350

90 (–)

2300

60 (10)

NB (NB)

–

143

145

127

138

125

130

125

0.20

7·10

-5

V2/1.14

850/1.0

35 / 27 / 17

>10

2.7

2.6

0.001

0.01

n.t.

1.20

0.35

0.50 - 0.70

88 - 90

< 0.8

1.586

201R

63 (70)

–

6 (120)

–

2350

90 (–)

2300

65 (10)

NB (NB)

–

144

145

127

138

125

130

125

0.20

7·10

-5

V2/1.14

850/1.0

35 / 27 / 17

>10

2.7

2.6

0.001

0.01

n.t.

1.20

0.35

0.50 - 0.70

88 - 90

< 0.8

1.586

263R

63 (70)

–

6 (120)

–

2350

90 (–)

2300

60 (10)

NB (NB)

–

143

145

127

138

125

130

125

0.20

7·10

-5

V2/1.47

850/1.0

n.t./n.t./ 17

>10

3.0

2.9

0.001

0.01

n.t.

1.20

0.35

0.50 - 0.70

88 - 90

< 0.8

1.586

203R

63 (70)

–

6 (120)

–

2350

90 (–)

2300

65 (10)

NB (NB)

–

144

145

127

138

125

130

125

0.20

7·10

-5

V2/1.47

850/1.0

n.t./n.t./ 17

>10

3.0

2.9

0.001

0.01

n.t.

1.20

0.35

0.50 - 0.70

88 - 90

< 0.8

1.586

UL94 in-house tested

)

LOI of 121R, 141R and 101R is 28

)

1141R and 101R is 35 / 27 / 17

)

Relative permittivity at 50 Hz of

121R, 141R and 101R is 2.7

page 21

page 20

page 18

)

Relative permittivity at 1 MHz of 121R, 141R and 101R is 2.6

)

MVR of OQ1020LN at 250°C/1.20 kg

)

MVR of 154, PKG1643 and 2034E at 80°C/3.80 kg

)

MVR of ML3324 and ML3290 at 300°C/2.16 kg

L e x a n P r o f i l e 3 P r o d u c t S e l e c t i o n p a g e 2 0

Typical Properties

Typical values only.

Not to be used for

specification purposes.

NB : not broken · – : not relevant · n.t.: not tested

Mechanical

Tens. stress

y (b)

Tens. strain

y (b)

Tens. modulus

Flex. stress

y (b)

Flex. modulus

Hardness

Ball

Abrasion

Taber

Impact

Izod notch.

23° (-30°) C

unnotch.

23° (-30°) C

Thermal

Vicat A/50

B/50

B/120

HDT / Ae 1.80 MPa

/ Be 0.45 Mpa

Ball Pressure

RTI

Electrical

Mech. with Impact

without Impact

Thermal conductivity

CTE flow

Flammability

UL94

LOI

Glow wire

Electrical

Diel. str. oil 0.8 / 1.6 / 3.2 mm

Surface resistivity

Volume resistivity

Rel. permitt.

50 Hz

1 MHz

Dissipation f. 50 Hz

1 MHz

CTI

Physical

Density

Water abs.

23°C

Mould shrink. flow

Optical

Light transmission

Haze

Refractive index

Rheological

MVR

Unit

MPa

mg/1000 cy

kJ/m

°C

W/m°C

1/°C

class at mm

°C at mm

kV/mm

Ohm

Ohm·cm

—

g/cm

—

/10 min

UL94 in-house tested

)

LOI of 121R, 141R and 101R is 28

)

1141R and 101R is 35 / 27 / 17

)

Relative permittivity at 50 Hz of

121R, 141R and 101R is 2.7

Unreinforced Multi purpose

low

viscosity

medium

viscosity

high

viscosity

medium

viscosity

Injection moulding

flame retarded UL94V0

low to medium

viscosity

page 19

page 21

920

63 (60)

–

6 (85)

–

2350

– (–)

2300

9 (7)

NB (NB)

–

140

141

122

133

125

130

120

125

0.20

7·10

-5

V0/1.04

850/1.0

960/1.6

n.t./n.t./ 17

>10

3.0

2.9

0.001

0.01

225

1.20

0.35

0.50 - 0.70

–

923

63 (60)

–

6 (85)

–

2350

– (–)

2300

9 (7)

NB (NB)

–

140

141

122

133

125

130

120

125

0.20

7·10

-5

V0/1.00

850/1.0

960/1.6

n.t./n.t./ 17

>10

–

2.9

0.001

0.01

225

1.20

0.35

0.50 - 0.70

–

940

63 (60)

–

6 (85)

–

2350

– (–)

2300

12 (11)

NB (NB)

150

141

142

125

136

125

130

120

125

0.20

7·10

-5

V0/1.04

850/1.0

960/1.6

n.t./n.t./ 17

>10

3.0

2.9

0.001

0.01

225

1.20

0.35

0.50 - 0.70

–

9.5

943

63 (60)

–

6 (85)

–

2350

– (–)

2300

12 (11)

NB (NB)

–

141

142

125

136

125

130

120

125

0.20

7·10

-5

V0/1.00

850/1.0

960/1.6

n.t./n.t./ 17

>10

3.0

2.9

0.001

0.01

225

1.20

0.35

0.50 - 0.70

–

9.5

950

63 (65)

–

6 (100)

–

2350

– (–)

2300

15 (–)

NB (NB)

–

141

145

127

138

125

130

120

125

0.20

7·10

-5

V0/1.04

5VA/3.05

850/1.0

960/1.6

n.t./n.t./ 17

>10

3.0

2.9

0.001

0.01

n.t.

1.20

0.35

0.50 - 0.70

–

6.5

920A

63 (60)

–

6 (85)

–

2350

– (–)

2300

10 (–)

NB (NB)

–

141

142

124

135

125

130

120

125

0.20

7·10

-5

V0/3.05

850/1.0

960/1.6

35 / 27 / 17

>10

2.7

2.6

0.001

0.01

n.t.

1.20

0.35

0.50 - 0.70

n.t.

1.586

923A

63 (60)

–

6 (85)

–

2350

– (–)

2300

10 (–)

NB (NB)

–

141

142

124

135

125

130

120

125

0.20

7·10

-5

V0/3.20

850/1.0

960/1.6

n.t./n.t./ 17

>10

–

2.9

0.001

0.01

n.t.

1.20

0.35

0.50 - 0.70

n.t.

1.586

940A

63 (65)

–

6 (100)

–

2350

– (–)

2300

12 (10)

NB (NB)

150

141

142

125

136

125

130

120

125

0.20

7·10

-5

V0/3.05

850/1.0

960/1.6

35 / 27 / 17

>10

2.7

2.6

0.001

0.01

225

1.20

0.35

0.50 - 0.70

n.t.

1.586

9.5

943A

63 (65)

–

6 (100)

–

2350

– (–)

2300

12 (10)

NB (NB)

–

141

142

125

136

125

130

120

125

0.20

7·10

-5

V0/3.20

850/1.0

960/1.6

n.t./n.t./ 17

>10

3.0

2.9

0.001

0.01

n.t.

1.20

0.35

0.50 - 0.70

n.t.

1.586

9.5

)

Relative permittivity at 1 MHz of 121R, 141R and 101R is 2.6

)

MVR of OQ1020LN at 250°C/1.20 kg

)

MVR of 154, PKG1643 and 2034E at 80°C/3.80 kg

)

MVR of ML3324 and ML3290 at 300°C/2.16 kg

L e x a n P r o f i l e 3 P r o d u c t S e l e c t i o n p a g e 2 1

Typical Properties

Typical values only.

Not to be used for

specification purposes.

NB : not broken · – : not relevant · n.t.: not tested

Mechanical

Tens. stress

y (b)

Tens. strain

y (b)

Tens. modulus

Flex. stress

y (b)

Flex. modulus

Hardness

Ball

Abrasion

Taber

Impact

Izod notch.

23° (-30°) C

unnotch.

23° (-30°) C

Thermal

Vicat A/50

B/50

B/120

HDT / Ae 1.80 MPa

/ Be 0.45 Mpa

Ball Pressure

RTI

Electrical

Mech. with Impact

without Impact

Thermal conductivity

CTE flow

Flammability

UL94

LOI

Glow wire

Electrical

Diel. str. oil 0.8 / 1.6 / 3.2 mm

Surface resistivity

Volume resistivity

Rel. permitt.

50 Hz

1 MHz

Dissipation f. 50 Hz

1 MHz

CTI

Physical

Density

Water abs.

23°C

Mould shrink. flow

Optical

Light transmission

Haze

Refractive index

Rheological

MVR

UL94 in-house tested

)

LOI of 121R, 141R and 101R is 28

)

1141R and 101R is 35 / 27 / 17

)

Relative permittivity at 50 Hz of

121R, 141R and 101R is 2.7

Unreinforced Lighting

Unreinforced Optical

medium

viscosity

low

viscosity

very low

viscosity

high

viscosity

medium

viscosity

high

viscosity

Injection moulding

flame retarded CSTB M2

Unreinforced Multi purpose

lens system · optimal clarity

data storage

eyewear

high reflectivity

low to medium

viscosity

page 20

page 22

2014R

65 (70)

–

6 (100)

–

2350

95 (–)

2300

100

8 (8)

NB (NB)

–

144

145

129

139

125

110

125

0.20

7·10

-5

V2/1.47

850/1.0

960/3.2

35 / 27 / 17

>10

2.7

2.6

0.001

0.01

n.t.

1.24

0.32

0.40 - 0.60

88 - 90

< 0.8

1.586

8.5

2034

65 (70)

–

6 (100)

–

2350

95 (–)

2300

100

8 (8)

NB (NB)

–

144

145

129

140

125

n.t.

0.20

7·10

-5

V0/2.50

V2/1.50

850/1.0

960/3.2

n.t./n.t./n.t.

>10

3.0

2.9

0.001

0.01

n.t.

1.24

0.32

0.40 - 0.60

88 - 90

< 0.8

1.586

8.5

LS1

63 (65)

–

6 (100)

–

2350

90 (–)

2300

12 (10)

NB (NB)

–

140

141

122

133

125

130

125

0.20

7·10

-5

HB/1.47

850/1.0

n.t./n.t./ 17

>10

3.0

2.9

0.001

0.01

n.t.

1.20

0.35

0.50 - 0.70

88 - 90

< 0.8

1.586

LS2

63 (70)

–

6 (120)

–

2350

90 (–)

2300

25 (10)

NB (NB)

–

141

142

125

136

125

130

125

0.20

7·10

-5

HB/1.47

850/1.0

n.t./n.t./ 17

>10

3.0

2.9

0.001

0.01

n.t.

1.20

0.35

0.50 - 0.70

88 - 90

< 0.8

1.586

LS3

63 (70)

–

6 (120)

–

2350

90 (–)

2300

60 (10)

NB (NB)

–

144

145

127

138

125

130

125

0.20

7·10

-5

HB/1.47

850/1.0

n.t./n.t./ 17

>10

3.0

2.9

0.001

0.01

n.t.

1.20

0.35

0.50 - 0.70

88 - 90

< 0.8

1.586

OQ4320

63 (64)

–

6 (120)

–

2350

95 (–)

2300

n.t.

25 (11)

NB (NB)

–

141

142

124

136

125

n.t.

0.20

7·10

-5

–

850/1.0

n.t./n.t./n.t.

>10

n.t.

0.001

0.01

n.t.

1.20

0.35

0.50 - 0.70

88 - 90

< 0.8

1.586

OQ1020LN

60 (50)

–

6 (>60)

–

2300

85 (–)

2300

n.t.

10 (5)

NB (NB)

–

140

142

122

133

125

n.t.

0.20

7·10

-5

–

n.t.

850/1.0

n.t./n.t./n.t.

>10

n.t.

0.001

0.01

n.t.

1.20

0.35

0.50 - 0.70

>90

< 0.7

1.586

)

ML3042

60 (50)

–

6 (75)

–

2600

90 (–)

2500

n.t.

50 (15)

NB (NB)

–

143

145

n.t.

125

n.t.

0.20

6·10

-5

–

850/1.0

35 / 27 / 17

>10

2.7

2.6

0.001

0.01

250

1.33

0.35

0.50 - 0.70

–

)

Relative permittivity at 1 MHz of 121R, 141R and 101R is 2.6

)

MVR of OQ1020LN at 250°C/1.20 kg

)

MVR of 154, PKG1643 and 2034E at 80°C/3.80 kg

)

MVR of ML3324 and ML3290 at 300°C/2.16 kg

L e x a n P r o f i l e 3 P r o d u c t S e l e c t i o n p a g e 2 2

Typical Properties

Typical values only.

Not to be used for

specification purposes.

NB : not broken · – : not relevant · n.t.: not tested

Mechanical

Tens. stress

y (b)

Tens. strain

y (b)

Tens. modulus

Flex. stress

y (b)

Flex. modulus

Hardness

Ball

Abrasion

Taber

Impact

Izod notch.

23° (-30°) C

unnotch.

23° (-30°) C

Thermal

Vicat A/50

B/50

B/120

HDT / Ae 1.80 MPa

/ Be 0.45 Mpa

Ball Pressure

RTI

Electrical

Mech. with Impact

without Impact

Thermal conductivity

CTE flow

Flammability

UL94

LOI

Glow wire

Electrical

Diel. str. oil 0.8 / 1.6 / 3.2 mm

Surface resistivity

Volume resistivity

Rel. permitt.

50 Hz

1 MHz

Dissipation f. 50 Hz

1 MHz

CTI

Physical

Density

Water abs.

23°C

Mould shrink. flow

Optical

Light transmission

Haze

Refractive index

Rheological

MVR

Unit

MPa

mg/1000 cy

kJ/m

°C

W/m°C

1/°C

class at mm

°C at mm

kV/mm

Ohm

Ohm·cm

—

g/cm

—

/10 min

UL94 in-house tested

)

LOI of 121R, 141R and 101R is 28

)

1141R and 101R is 35 / 27 / 17

)

Relative permittivity at 50 Hz of

121R, 141R and 101R is 2.7

Glass Reinforced

10%

medium

viscosity

Injection moulding

normal glass

10%
high

viscosity

20%
high

viscosity

30%
high

viscosity

40%
high

viscosity

15%

low - medium

viscosity

20%

low - medium

viscosity

page 21

page 23

500R

– (–)

3300

95 (–)

3400

115

8 (8)

NB (NB)

–

141

143

132

140

125

130

125

0.21

4 ·10

-5

V0/1.47

5VA/3.05

850/1.0

960/1.0

33 / 25 / 16

>10

3.0

2.9

0.001

0.01

175

1.25

0.31

0.20 - 0.60

–

503R

– (–)

3300

95 (–)

3400

110

8 (8)

NB (NB)

150

141

143

132

140

125

120

110

120

0.21

4 ·10

-5

V0/1.47

5VA/3.05

850/1.0

960/1.0

n.t./n.t./ 16

>10

3.1

3.0

0.001

0.01

175

1.25

0.31

0.20 - 0.60

–

ML3019

– (–)

3300

100 (–)

3400

136

– (–)

40 (–)

–

140

142

135

142

125

115

0.21

4 ·10

-5

V0/1.60

850/1.0

960/3.2

n.t./n.t./ 16

>10

n.t.

0.001

0.01

n.t.

1.27

0.31

0.20 - 0.55

–

2814R

– (–)

3300

– (95)

3400

131

6 (6)

– (–)

150

141

143

132

140

125

n.t.

0.18

4 ·10

-5

V0/1.47

850/1.0

960/1.6

35 / 27 / 17

>10

2.7

2.6

0.001

0.01

125

1.25

0.31

0.20 - 0.55

–

1278R

– (–)

5200

– (120)

5000

160

8 (8)

40 (40)

151

141

143

134

140

125

120

0.22

3 ·10

-5

V1/1.57

850/1.0

960/3.2

n.t./n.t./ 16

>10

n.t.

0.001

0.01

150

1.35

0.29

0.20 - 0.50

–

3412R

– (–)

6000

– (120)

5500

125

8 (6)

30 (30)

155

147

145

139

144

125

130

125

130

0.22

3 ·10

-5

V0/0.80

850/1.0

960/1.6

33 / 25 / 16

>10

3.0

2.9

0.001

0.01

150

1.35

0.29

0.20 - 0.50

–

3413R

– (–)

100

– (–)

9000

– (130)

7000

n.t.

8 (6)

30 (30)

–

147

145

139

144

125

130

125

130

0.22

3 ·10

-5

V0/1.50

850/1.0

960/1.6

33 / 25 / 16

>10

3.0

2.9

0.001

0.01

n.t.

1.44

0.26

0.10 - 0.40

–

3414R

– (–)

100

– (–)

10000

– (145)

8500

145

8 (6)

30 (30)

155

147

145

139

144

125

130

125

130

0.22

2·10

-5

V0/1.50

850/1.0

960/1.6

33 / 25 / 16

>10

3.0

2.9

0.001

0.01

125

1.52

0.23

0.10 - 0.30

–

ML3260

– (–)

4500

– (95)

4000

n.t.

8 (8)

80 (80)

–

141

143

130

138

125

n.t.

0.22

4 ·10

-5

V1/1.60

850/1.0

960/3.2

35 / 27 / 17

>10

2.7

2.6

0.001

0.01

175

1.31

0.30

0.20 - 0.50

–

)

Relative permittivity at 1 MHz of 121R, 141R and 101R is 2.6

)

MVR of OQ1020LN at 250°C/1.20 kg

)

MVR of 154, PKG1643 and 2034E at 80°C/3.80 kg

)

MVR of ML3324 and ML3290 at 300°C/2.16 kg

30%
high

viscosity

L e x a n P r o f i l e 3 P r o d u c t S e l e c t i o n p a g e 2 3

Typical Properties

Typical values only.

Not to be used for

specification purposes.

NB : not broken · – : not relevant · n.t.: not tested

Mechanical

Tens. stress

y (b)

Tens. strain

y (b)

Tens. modulus

Flex. stress

y (b)

Flex. modulus

Hardness

Ball

Abrasion

Taber

Impact

Izod notch.

23° (-30°) C

unnotch.

23° (-30°) C

Thermal

Vicat A/50

B/50

B/120

HDT / Ae 1.80 MPa

/ Be 0.45 Mpa

Ball Pressure

RTI

Electrical

Mech. with Impact

without Impact

Thermal conductivity

CTE flow

Flammability

UL94

LOI

Glow wire

Electrical

Diel. str. oil 0.8 / 1.6 / 3.2 mm

Surface resistivity

Volume resistivity

Rel. permitt.

50 Hz

1 MHz

Dissipation f. 50 Hz

1 MHz

CTI

Physical

Density

Water abs.

23°C

Mould shrink. flow

Optical

Light transmission

Haze

Refractive index

Rheological

MVR

UL94 in-house tested

)

LOI of 121R, 141R and 101R is 28

)

1141R and 101R is 35 / 27 / 17

)

Relative permittivity at 50 Hz of

121R, 141R and 101R is 2.7

Glass Reinforced

Specialties

short glass

impact

modified

reduced property

profile

gamma

sterilizable

medium

viscosity

medium

viscosity

low

viscosity

Injection moulding

low to medium

viscosity

page 22

ML3513

– (–)

4500

– (120)

4500

142

8 (8)

40 (40)

153

147

150

140

145

125

n.t.

0.22

2.8 ·10

-5

V0/1.50

850/1.0

960/3.2

n.t./n.t./ 16

>10

3.3

0.001

0.01

150

1.42

0.26

0.20 - 0.40

–

ML3041

60 (63)

–

6 (105)

–

2350

88 (–)

2300

58 (17)

NB (NB)

–

143

141

121

–

125

n.t.

0.20

7.0·10

-5

V2/1.00

850/1.0

35 / 27 / 17

>10

2.7

2.6

0.001

0.01

n.t.

1.20

0.35

0.50 - 0.70

–

ML3400

55 (57)

–

6 (100)

–

2100

80 (–)

2150

58 (50)

NB (NB)

–

140

142

121

133

125

n.t.

0.20

7.0·10

-5

–

850/1.0

n.t./n.t./ 17

>10

3.0

2.9

0.001

0.01

n.t.

1.20

0.35

0.60 - 0.80

–

ML3459

55 (65)

–

7 (120)

–

2100

80 (–)

2150

n.t.

65 (40)

NB (NB)

–

138

140

122

131

125

n.t.

0.20

7.0·10

-5

–

850/1.0

n.t./n.t./ 17

>10

n.t.

0.001

0.01

175

1.20

0.35

0.60 - 0.80

–

GR1210

62 (55)

–

6 (85)

–

2300

92 (–)

2400

n.t.

11 (8)

NB (NB)

–

131

113

125

n.t.

0.15

–

850/1.0

n.t./n.t./ 17

>10

2.8

2.7

0.001

0.01

275

1.20

0.35

0.50 - 0.70

1.0

n.t.

ML3562

– (–)

–

– (–)

–

– (–)

2100

n.t.

15 (10)

NB (NB)

–

138

120

–

125

n.t.

0.20

7.0·10

-5

V2/1.00

–

850/1.0

n.t./n.t./ 17

>10

n.t.

0.001

0.01

n.t.

1.20

0.35

0.50 - 0.70

–

ML3286

– (–)

–

– (95)

4500

n.t.

NB (20)

– (–)

–

120

–

125

n.t.

0.22

3.0·10

-5

–

850/1.0

n.t./n.t./ 16

>10

n.t.

0.001

0.01

n.t.

1.33

0.30

0.20 - 0.55

–

)

Relative permittivity at 1 MHz of 121R, 141R and 101R is 2.6

)

MVR of OQ1020LN at 250°C/1.20 kg

)

MVR of 154, PKG1643 and 2034E at 80°C/3.80 kg

)

MVR of ML3324 and ML3290 at 300°C/2.16 kg

L e x a n P r o f i l e 3 P r o d u c t S e l e c t i o n p a g e 2 4

Typical Properties

Typical values only.

Not to be used for

specification purposes.

NB : not broken · – : not relevant · n.t.: not tested

Mechanical

Tens. stress

y (b)

Tens. strain

y (b)

Tens. modulus

Flex. stress

y (b)

Flex. modulus

Hardness

Ball

Abrasion

Taber

Impact

Izod notch.

23° (-30°) C

unnotch.

23° (-30°) C

Thermal

Vicat A/50

B/50

B/120

HDT / Ae 1.80 MPa

/ Be 0.45 Mpa

Ball Pressure

RTI

Electrical

Mech. with Impact

without Impact

Thermal conductivity

CTE flow

Flammability

UL94

LOI

Glow wire

Electrical

Diel. str. oil 0.8 / 1.6 / 3.2 mm

Surface resistivity

Volume resistivity

Rel. permitt.

50 Hz

1 MHz

Dissipation f. 50 Hz

1 MHz

CTI

Physical

Density

Water abs.

23°C

Mould shrink. flow

Optical

Light transmission

Haze

Refractive index

Rheological

MVR

Unit

MPa

mg/1000 cy

kJ/m

°C

W/m°C

1/°C

class at mm

°C at mm

kV/mm

Ohm

Ohm·cm

—

g/cm

—

/10 min

UL94 in-house tested

)

LOI of 121R, 141R and 101R is 28

)

1141R and 101R is 35 / 27 / 17

)

Relative permittivity at 50 Hz of

121R, 141R and 101R is 2.7

Linear Polymers

Branched Polymers

Flame

Retarded
CSTB M2

profile

extrusion

blow moulding

twin-wall

sheet extrusion

solid

sheet

flame retarded

extrusion

blow

moulding

Extrusion

hydrolytic

stability

hydrolytic

stability

high melt

strength

high melt

strength

ML3021A

60 (65)

–

6 (100)

–

2400

85 (–)

2300

60 (13)

NB (NB)

150

143

146

131

140

125

n.t.

0.17

6.7·10

-5

HB/1.60

850/1.0

960/3.2

35 / 27 / 17

>10

2.7

2.6

0.001

0.01

225

1.20

0.35

0.50 - 0.70

88 - 90

< 0.8

1.586

ML3403

60 (65)

–

7 (120)

–

2350

85 (–)

2300

n.t.

65 (13)

NB (NB)

–

146

148

127

142

125

n.t.

0.20

7.0·10

-5

n.t.

850/1.0

n.t.

n.t./n.t./n.t.

>10

2.7

0.001

0.01

n.t.

1.20

0.35

0.50 - 0.70

88 - 90

< 0.8

1.586

154

60 (65)

–

7 (120)

–

2350

100 (–)

2300

60 (10)

NB (NB)

–

146

143

124

–

125

n.t.

0.20

7.0·10

-5

n.t.

850/1.0

n.t.

n.t./n.t./n.t.

>10

3.0

2.9

0.001

0.01

n.t.

1.20

0.35

0.50 - 0.70

88 - 90

< 0.8

1.586

)

PKG1643

60 (65)

–

7 (120)

–

2300

100 (–)

2500

60 (10)

NB (NB)

148

146

143

124

136

125

n.t.

0.20

7.0·10

-5

n.t.

850/1.0

n.t.

n.t./n.t./n.t.

>10

n.t.

0.001

0.01

n.t.

1.20

0.35

0.50 - 0.70

88 - 90

< 0.8

1.586

)

ML3324

60 (65)

–

7 (120)

–

2300

100 (–)

2300

60 (10)

NB (NB)

148

146

143

124

136

125

n.t.

0.20

7.0·10

-5

HB/1.50

n.t.

850/1.0

n.t.

n.t./n.t./n.t.

>10

n.t.

0.001

0.01

n.t.

1.20

0.35

0.50 - 0.70

88 - 90

< 0.8

1.586

)

ML3290

60 (65)

–

6 (100)

–

2350

95 (–)

2300

15 (10)

NB (NB)

148

146

135

124

136

125

n.t.

0.20

7.0·10

-5

V0/2.00

850/1.0

960/3.2

35 / 27 / 17

>10

2.7

2.6

0.001

0.01

n.t.

1.20

0.35

0.50 - 0.70

88 - 90

< 0.8

1.586

)

2034E

65 (70)

–

6 (100)

–

2350

90 (–)

2300

n.t.

8 (8)

NB (NB)

–

144

148

129

–

125

n.t.

0.20

7.0·10

-5

n.t.

850/1.0

n.t.

n.t./n.t./n.t.

>10

n.t.

0.001

0.01

n.t.

1.24

0.32

0.40 - 0.60

88 - 90

< 0.8

1.586

)

Relative permittivity at 1 MHz of 121R, 141R and 101R is 2.6

)

MVR of OQ1020LN at 250°C/1.20 kg

)

MVR of 154, PKG1643 and 2034E at 80°C/3.80 kg

)

MVR of ML3324 and ML3290 at 300°C/2.16 kg

L e x a n P r o f i l e 3 P r o d u c t S e l e c t i o n p a g e 2 5

Typical Properties

Typical values only.

Not to be used for

specification purposes.

NB : not broken · – : not relevant · n.t.: not tested

Mechanical

Tens. stress

y (b)

Tens. strain

y (b)

Tens. modulus

Flex. stress

y (b)

Flex. modulus

Hardness

Ball

Abrasion

Taber

Impact

Izod notch.

23° (-30°) C

unnotch.

23° (-30°) C

Thermal

Vicat A/50

B/50

B/120

HDT / Ae 1.80 MPa

/ Be 0.45 Mpa

Ball Pressure

RTI

Electrical

Mech. with Impact

without Impact

Thermal conductivity

CTE flow

Flammability

UL94

LOI

Glow wire

Electrical

Diel. str. oil 0.8 / 1.6 / 3.2 mm

Surface resistivity

Volume resistivity

Rel. permitt.

50 Hz

1 MHz

Dissipation f. 50 Hz

1 MHz

CTI

Physical

Density

Water abs.

23°C

Mould shrink. flow

Optical

Light transmission

Haze

Refractive index

Rheological

MVR

FL900P

n.t. (n.t.)

n.t.

n.t. (n.t.)

n.t.

n.t. (n.t.)

n.t.

n.t. (n.t.)

n.t.

125

n.t.

0.15

3.5·10

-5

n.t.

n.t./n.t./n.t.

n.t.

2.3

n.t.

0.01

n.t.

0.95

0.35

0.50 - 0.70

–

FLC95

– (–)

–

– (–)

–

– (–)

–

– (–)

–

– / – / –

–

UL94 in-house tested

)

LOI of 121R, 141R and 101R is 28

)

1141R and 101R is 35 / 27 / 17

)

Relative permittivity at 50 Hz of

121R, 141R and 101R is 2.7

Glass

Reinforced

Structural foam

5% normal

glass

Blowing

Agent

chemical

concentrate

)

Relative permittivity at 1 MHz of 121R, 141R and 101R is 2.6

)

MVR of OQ1020LN at 250°C/1.20 kg

)

MVR of 154, PKG1643 and 2034E at 80°C/3.80 kg

)

MVR of ML3324 and ML3290 at 300°C/2.16 kg

4.1

General properties

Lexan polycarbonate is an
amorphous engineering
thermoplastic which displays high
levels of mechanical, optical,
electrical and thermal properties.
Its unique property profile includes
outstanding impact strength over a
wide range of temperatures, from
subzero to over 80°C.

A characteristic Lexan resin offers:

High transparency

Extreme toughness

Low uniform shrinkage

Dimensional stability

Consistent processibility

UV stability

Flame retardancy

Heat resistance

Wide colour availability

Lexan resin’s exceptional impact
strength and practical toughness
establish it as a first choice material
for many very demanding
applications across diverse industries.

Design calculations for Lexan resin
are no different than for any other
material. Physical properties of plastic
are dependent on the expected
temperature and stress levels. Once
this dependency is understood, and
the end-use environment has been
defined for an application, standard
engineering calculations can be used
to accurately predict part
performance. However, in designing
for Lexan it is important to take
into account the notch sensitivity
and lower hydrolytic stability of
polycarbonate resins.

4.2

Mechanical properties

In general, Lexan resin exhibits
excellent mechanical property
retention over a wide temperature
range.
As illustrated in

■

F I G U R E S

1 and 2 ,

Lexan resin’s tensile strength and
flexural modulus decrease slightly as
temperature increases. However, the
effect of temperature on impact
resistance is the reverse: as the
temperature decreases, Lexan resin
becomes slightly stiffer and slightly
more brittle.

P r o p e r t i e s a n d D e s i g n

■

F I G U R E

Tensile strength
as a function
of temperature

Lexan

3414R
3412R

500R
141R

ensile str

ength (MPa)

Temperature (°C)

140

120

100

-40

-20

100

■

F I G U R E

Flexural modulus
of Lexan 3414R,
3412R, 500R and
141R as a function
of temperature

Lexan

3414R
3412R

500R
141R

Flexural modulus (MPa)

Temperature (°C)

8000

7000

6000

5000

4000

3000

2000

1000

-40

-20

100

120

4.2.1

Impact strength

Lexan resin’s exceptional impact
strength and practical toughness
make parts virtually shatter-proof,
providing a high degree of safety and
durability in service in the toughest of
environments. The superior impact
resistance of Lexan polycarbonate
versus glass can be seen in

■

F I G U R E

3 .

At very low temperatures, impact
resistance can be further improved
by blending with other resins such
as ABS, as in Cycoloy

PC/ABS alloy,

or by blending with impact modifiers.

■

F I G U R E

4 , for example, compares

the Izod impact strength of impact
modified Lexan ML3400 resin with
a standard unmodified Lexan grade.
Lexan ML3459 resin offers superior
impact retention after painting with
various paint systems.

There are several factors which
determine the ability of a plastic part
to absorb impact energy.
In addition to the type of material
these factors include:

Wall thickness

Geometric shape and size

Operating temperature and
environment

Rate of loading

Stress state induced by loading

L e x a n P r o f i l e 4 P r o p e r t i e s a n d D e s i g n

■

F I G U R E

Tensile impact
of Lexan and glass
as a function of
temperature

Lexan

glass

ensile impact (KJ/m

)

Temperature (°C)

100

120

■

F I G U R E

Izod impact
strength of Lexan
as a function
of temperature

Lexan

impact

modified
standard

Izod notched impact (KJ/m

)

Temperature (°C)

100

-40

-30

-20

-10

For ductile polymers such as Lexan
resin, the load at which yield occurs
in a part is affected by the last three
factors. Of even more significance
to design is the fact that, under the
appropriate circumstances, the
impact behaviour of a ductile
polymer will undergo a transition
from a ductile and forgiving response
to a brittle and catastrophic one.
Usually this change in behaviour is
described in terms of a transition
temperature above which the failure
is more ductile by nature, and below
which it is more brittle, as illustrated
in

■

F I G U R E

5 .

Interpretation of ISO & ASTM impact
values

Impact properties can be very
sensitive to test specimen thickness
and molecular orientation. The
differences in specimen thickness as
used in ASTM and ISO may have an
important effect on impact values.

A change from 3 to 4 mm thickness
can even provide a transition of the
failure mode from ductile to brittle
behaviour at a given temperature,
through the influence of molecular
weight and specimen thickness on
Izod notched impact. This is
illustrated in

■

F I G U R E

6 . Materials

which already exhibit a brittle
fracture mode at 3 mm, such as
mineral and glass-reinforced grades,
will not be affected. Impact modified
grades will also not be affected as they
still exhibit a ductile failure mode at
greater than 4 mm.

Therefore, ISO and ASTM impact
values may be radically different for
exactly the same material. However,
the ductile brittle transition described
rarely plays a role in real life as almost
all parts are designed with less than
3 mm wall sections.

4.2.2

Stiffness

The Lexan resin family offers
designers a great deal of choice as
far as stiffness is concerned.
While stiffness values can vary greatly
from one grade to another, the
stiffness properties for an individual
grade will remain constant over a
wide temperature range from subzero
to 120°C. In accordance with ISO 178,
the flexural modulus values range
from 2300 MPa for unreinforced
grades to up to 3400 MPa for 10%
glass-reinforced grades, 5500 MPa for
20% glass-reinforced, 7000 MPa for
30% glass-reinforced and 8500 MPa
for 40% glass-reinforced grades.

L e x a n P r o f i l e 4 P r o p e r t i e s a n d D e s i g n

■

F I G U R E

Graph illustrating
effect of
temperature upon
impact response

Impact value

Temperature

brittle behaviour

ductile behaviour

ductile/brittle transition

■

F I G U R E

Influence of
specimen
thickness and
molecular weight
on Izod notched
impact properties
of Lexan

Lexan

101
121
141
161

Izod notched impact

Specimen thickness (mm)

ASTM

ISO

3.2 mm 4.0 mm

The stiffness of a part is defined as
the relationship between the load
and the deflection of a part. The
most important material property
for stiffness is the stress/strain curve.
In general, the Young’s modulus,
(ISO 527), which is determined from
the stress/strain curve, is the best
parameter to be used when
comparing the stiffness of materials.

■

F I G U R E

7 compares the tensile stress

and strain, showing modulus of
unreinforced Lexan 141R with 10%
glass-reinforced Lexan 500R and 20%
glass-reinforced Lexan 3412R. Lexan
500R shows an excellent combination
of energy absorption and modulus,
while Lexan 3412R has an ideal fit in
high modulus applications.

A further important consideration
in the calculation of part stiffness
is the temperature at which the
load is applied. As can be seen in

■

F I G U R E S

8 and 9 , the stress/strain

curves of thermoplastics are strongly
influenced by temperature.

L e x a n P r o f i l e 4 P r o p e r t i e s a n d D e s i g n

■

F I G U R E

Stress-strain
curve of Lexan
3412R, 500R
and 141R (23°C)

Lexan

3412R

500R
141R

ensile stress (MPa)

Strain (%)

■

F I G U R E

Stress-strain
curve of
Lexan 141R

-30°C

0°C

23°C
60°C
90°C

ensile stress (MPa)

Strain (%)

■

F I G U R E

Stress-strain
curve of
Lexan 3412R

-30°C

0°C

23°C
60°C
90°C

Stress (MPa)

Strain (%)

100

0.3

0.6

0.9

1.2

1.5

1.8

2.1

2.4

4.2.3

Strength

The strength of a part is defined as
the maximum load that can be
applied to a part without causing part
failure under given conditions.
In order to be able to determine the
strength of a part, failure has to be
first defined. The right definition of
failure depends on the application
and how much deformation is
allowed.

Material strength is a stress/strain
related property which is inherent
in the material. The tensile test
provides the most useful information
for engineering design. For unfilled

Lexan grades subjected to small
strains, the stress increases
proportionally with the strain.
However,early in the test non-linearity
will occur. In fact a close observation
of the stress/strain curve shows that a
proportional part does not exist. With
larger strains, yield will occur and the
maximum stress is reached. If the
strain is further increased, necking
will occur. The neck will propagate
through the structure until the
material fails.

The speed of deformation in the
application is vital. The differences
are shown for Lexan 500R in

■

F I G U R E

1 0 .

4.2.4

Behaviour over time

There are two types of phenomena
which should be considered. Static
time dependent phenomena such
as creep are caused by the single,
long-term loading of an application.
Dynamic time dependent
phenomena such as fatigue, on the
other hand, are produced by the
cyclic loading of an application.
Both types of behaviour are heavily
influenced by the operating
environment and component design.

L e x a n P r o f i l e 4 P r o p e r t i e s a n d D e s i g n

■

F I G U R E

1 0

Stress-strain
curve of
Lexan 500R (23°C)

10 %/sec

1 %/sec

0.1 %/sec

0.01 %/sec

Stress (MPa)

Strain (%)

4.2.4.1

Creep behaviour

Creep is defined as the increasing
rate of deformation of a geometrical
shape when subjected to a constant
long-term load. With plastics,
the creep rate is dependent on
temperature, load and time. At a
certain stress level, creep becomes
minimal and can be disregarded
in long-term, continuous-load
applications.

■

F I G U R E

1 1 shows that a key property

of Lexan resin is its predictable, low
creep behaviour even at higher loads.
This is due to the amorphous
structure and its inherent high heat
resistance. At higher temperatures,
the creep behaviour is increased as
can be seen in

■

F I G U R E

1 2 .

4.2.4.2

Fatigue endurance

Fatigue is an important design
consideration for parts subjected to
cyclic loading or vibration. Structural
components subjected to vibration,
components subjected to repeated
impacts, reciprocating mechanical
components, plastic snap-fit latches
and moulded-in plastic hinges are all
examples where fatigue can play an
important role. Cyclic loading can
result in mechanical deterioration
and fracture propagation through the
material, leading to ultimate failure.
When parts are subjected to cyclic
loading, fatigue failure can occur,
often at a stress level considerably
below the yield point of the material.

L e x a n P r o f i l e 4 P r o p e r t i e s a n d D e s i g n

■

F I G U R E

1 1

Deformation at
constant load
(creep) of Lexan
141R (23°C)

Strain (%)

Time (hrs)

3.6

3.2

2.8

2.4

2.0

1.6

1.2

0.8

0.4

40 MPa
35 MPa
30 MPa
25 MPa
20 MPa
15 MPa

■

F I G U R E

1 2

Deformation at
constant load
(creep) of Lexan
141R (15 MPa)

Strain (%)

Time (hrs)

1.8

1.6

1.4

1.2

1.0

0.8

0.6

-4

-3

-2

-1

23°C
60°C
90°C

In such applications, an uniaxial
fatigue diagram could be used to
predict product life. These curves
can be used to determine the fatigue
endurance limit, or the maximum
cycle stress that a material can
withstand without failure.

■

F I G U R E S

1 3 and 1 4 compare the

fatigue behaviour of an unfilled and
a filled Lexan grade.

Fatigue tests are usually conducted
under flexural conditions, though
tensile and torsional testing is also
possible. A specimen of material is
repeatedly subjected to a constant
deformation at a constant frequency,
and the number of cycles to failure
is recorded. The procedure is then
repeated over a range of deflections
or applied stresses. The test data are
usually presented as a plot of log
stress versus log cycles; this is
commonly referred to as an S - N
curve, as shown in

■

F I G U R E S

1 3

and 1 4 . S - N curves obtained under
laboratory conditions may be

regarded as “ideal”. However,
practical conditions usually
necessitate the use of a modified
fatigue limit, as other factors may
affect performance, including most
notably the type of loading, the size
of the component and the loading
frequency.

However, fatigue testing can only
provide an indication as to a given
material’s relative ability to survive
fatigue. It is therefore essential that
tests are performed on actual
moulded components, under actual
end-use operating conditions.

L e x a n P r o f i l e 4 P r o p e r t i e s a n d D e s i g n

■

F I G U R E

1 3

Uniaxial fatigue
test of Lexan 141
(frequency 5 Hz,
23°C)

Stress (MPa)

Cycles to failure

■

F I G U R E

1 4

Uniaxial fatigue
test of Lexan 500R
(frequency 5 Hz,
23°C)

Stress (MPa)

Cycles to failure

4.3

Thermal properties

The property profile of Lexan
resin includes very good thermal
properties.
However, all thermoplastics will
soften at elevated temperatures.
The most common thermal test is
the Vicat Softening Temperature,
as shown in

■

F I G U R E

1 5 , which

measures the temperature at which
a plastic starts to soften rapidly.

A second commonly used thermal test
is the Heat Deflection Temperature,
which in amorphous materials such as
Lexan resin is strongly related to the
glass transition temperature ( T

Other thermal tests include the Ball
Pressure Test, IEC 695-10-2,
according to which almost all Lexan
resins pass at 125°C.

In accordance with UL746B, Lexan
resins have been granted a Relative
Thermal Index (RTI) of between
80°C and 130°C. There can be up to
three independent RTI ratings
assigned to a material: electrical,
mechanical with impact and
mechanical without impact.

4.4

Flammability

Non-flame retarded standard Lexan
resins in addition to the flame
retarded Lexan 500 and 900 series all
offer halogen-free flame retardancy
according to DIN VDE 472, part 815.

The most widely accepted
flammability performance standards
for plastics are UL ratings which
identify a material’s ability to
extinguish a flame once ignited.

According to UL Subject 94, the

Lexan 900 series has been rated V0 at
low thicknesses (e.g. 943 is UL94 V0
at 1.04 mm), Lexan 3412R is rated V0
at 0.8 mm, while the Lexan 500 series
has been rated V0 at 1.5 mm and 5VA
at 3 mm. A complete overview of the
UL 94 classifications for Lexan is
given in

■

TA B L E

1 . It should be noted

that each Lexan resin tested may
receive several ratings depending on
colour and/or thickness.

In addition, Glow Wire Test results,
according to IEC 695-2-1, are
dependent on the thickness of the
material sample and the actual test
temperature. Almost all Lexan grades
pass the 850°C test at 1 mm, while
most of the flame retarded grades will
pass the 960°C test at 1.6 mm. Special
grades are available which pass the
960°C test at 1 mm.

L e x a n P r o f i l e 4 P r o p e r t i e s a n d D e s i g n

■

F I G U R E

1 5

Vicat indentation
vs. temperature
of Lexan 161R
(ISO 179; Shear
rate: 120°C/hr;
weight: 50 N)

Indentation (mm)

Temperature (°C)

1.2

1.0

0.8

0.6

0.4

0.2

-0.2

100

120

140

160

UL rating

Thickness

Lexan grades

UL94 HB

< 1.5 mm

103R, 123R, 143R, 163R, LS1, LS2, LS3, ML3322

1.5 - 3.0 mm

1xy series, ML3021A, ML3324

UL94 V2

< 1.5 mm

201R, 221R, 261R, HF1110R, HF1140R,

ML3021A, ML3041

1.5 - 3.0 mm

2014R, 2034, 2xy series, 910A, 920A, 940A,

950A, 923A, 943A, 953A, ML3290, ML3485

UL94 V1

1.5 - 3.0 mm

1278R, ML3260

UL94 V0

< 1.5 mm

3412, 923, 940, 943

1.5 - 2.5 mm

2814R, 3413R, 500R, 503R, 920, 950,

ML3290, ML3513

> 2.5 mm

2014R, 2034, 910A, 920A, 940A, 943A, 950A,

953A, ML3260

> 4.0 mm

FL900P

UL94 5VA

> 3.0 mm

500R, 503R, 950

■

TA B L E

UL recognition for flammability

In accordance with ISO 4589, Lexan
general purpose grades have a limited
oxygen index (LOI) of 25 - 28%, while
Lexan 900A grades have an LOI of
38%. This means that all Lexan resins
are self-extinguishing.

■

F I G U R E

1 6

compares the LOI of various GE
Plastics’ resins.

This combination of properties makes
Lexan resin an ideal material for a
variety of electrotechnical
applications.

4.4.1

Transportation industry
regulations

Lexan resin is widely used in a variety
of transportation applications.
Stringent flammability requirements
are enforced depending on the
industry and the country.

In railway industry applications in
France, for example, the I, F, M
classification according to
NF F 16-101 is important, while in
Germany applications are subject to
DIN 5510. Typical values for Lexan
for both regulations are given in

■

TA B L E S

2 and 3 , with the

understanding that these values
can be thickness and/or colour
dependent.

In aircraft applications, Lexan resin’s
compliance with the requirements of
Airbus standard ABD0031 for smoke
evolution and toxicity is detailed in

■

TA B L E

4 .

According to the federal motor
vehicle safety standard FMVSS302,
all Lexan grades pass at thicknesses
>1.5 mm, while flame retarded
grades even pass at thicknesses below
1.5 mm.

L e x a n P r o f i l e 4 P r o p e r t i e s a n d D e s i g n

■

F I G U R E

1 6

Limited oxygen
index (ISO 4589)

Ultem *

Lexan

Noryl

Valox

Cycoloy

Noryl GTX

Cycolac

Noryl Xtra

Xenoy

→

inherent flame redardancy

burns

extinguishes

21 % O

in air

I-class

F-class

M-class

Lexan 2034

Lexan 2814R

Lexan 500R

–

Lexan 943

–

Lexan 943A

–

■

TA B L E

Typical values for Lexan according to
transportation industry regulation NF F 16-101

FAR25853

Smoke D4min

Toxicity

Lexan 500R

< 200

pass

Lexan 940

< 200

pass

Lexan 950

< 200

pass

Lexan 950A

< 200

pass

Lexan ML3290

< 200

pass

■

TA B L E

Typical values for Lexan according to
Airbus standard ABD0031

Fire

Smoke

Dripping

Lexan 503R

SR2

ST2

Lexan 923

SR2

ST2

■

TA B L E

Typical values for Lexan according to
transportation industry regulation DIN5510

4.5

Electrical properties

As an organic material, Lexan resin
is an excellent electrical insulator.

4.5.1

Dielectric strength

As can be seen in

■

F I G U R E

1 7 , the

dielectric strength is non-linear with
the thickness. Standard Lexan resin
typically exhibits a dielectric strength
of 17 kV/mm at 3.2 mm, 27 kV/mm at
1.5 mm, 35 kV/mm at 1 mm and
67 kV/mm at 0.25 mm thickness.

4.5.2

Relative permittivity

■

F I G U R E

1 8 shows that the relative

permittivity values of Lexan resins are
intermediate to high when compared
with other polymers. The higher
values indicate a greater insulating
quality.

4.5.3

Dissipation factor

As can be seen in

■

F I G U R E

1 9 , the

electrical dissipation factor of Lexan
resins over a wide range of
frequencies varies from intermediate
to high when compared with other
polymers; the smaller values for the
dissipation factor correspond to a
better dielectric material. In addition
to frequency, temperature and
contaminants such as moisture affect
the dissipation factor.

L e x a n P r o f i l e 4 P r o p e r t i e s a n d D e s i g n

■

F I G U R E

1 8

Relative
permittivity at
60Hz and 50%
RH of unfilled
materials

Valox

Ultem

Lexan

Noryl

Valox

Ultem

Lexan

Noryl

Dielectric constant

Temperature (°C)

5.0

4.5

4.0

3.5

3.0

2.5

2.0

100

120

140

160

180

■

F I G U R E

1 9

Dissipation factor
at 23°C of unfilled
materials

Dissipation factor

Frequency (Hz)

-1

-2

-3

-4

■

F I G U R E

1 7

Dielectric
strength of
unfilled Lexan
as a function
of thickness

Dielectric str

ength (kV/mm)

Thickness (mm)

0.5

1.5

2.5

3.5

4.6

Aesthetics and optical
properties

Lexan resin is a naturally transparent,
‘water white’ material with excellent
aesthetic properties. It is available in
a wide choice of colours, many of
which have transparent, translucent,
opalescent and opaque versions.
In addition, Lexan resin consistently
reproduces mould surface finish
with great accuracy. This provides
designers with top quality, high gloss
or textured surface finishes.

Lexan resin has excellent light
transparency which is close to that of
glass, and a very high refractive index
of 1.586. Its highest transmission rate
is in the visible light and infrared
region, as shown in

■

F I G U R E

2 0 .

■

F I G U R E

2 1 shows the excellent light

transmission of standard natural
colour Lexan 141R resin at different
thicknesses. The light transmission
of transparent Lexan resins can be
changed if required. Grades such as
Lexan 143R-111 and Lexan LS2-111
have a built-in UV screen to filter out
UV radiation up to 380 nm. Modified
grades such as Lexan OQ4320 will
even reach 400 nm, thereby providing
additional sun protection without
affecting the transmission in the

L e x a n P r o f i l e 4 P r o p e r t i e s a n d D e s i g n

280 - 315 nm

UV-B middle UV region

315 - 280 nm

UV-A middle UV region

380 - 780 nm

visible light region

780 - 1400 nm

near infra red region

1400 - 3000 nm

middle infra red region

■

F I G U R E

2 0

Light transmission
of UV stabilized
Lexan

Light transmission (%)

Wavelength (nm)

100

800

1600

2400

3200

visible

infra red

■

F I G U R E

2 1

Light transmission
of Lexan 141R
as a function
of thickness for
standard natural
colour

ransmission (%)

1 mm

2 mm

3 mm

4 mm

5 mm

6 mm

visible region. Special colours provide
a high light transmission in the
infrared region only, which blocks all
light in the visible light region for
applications such as remote control
panels, as illustrated in

■

F I G U R E

2 2 .

Opalescent colours provide partial
light diffusion for the Lighting
Industry. The transmission at a given
thickness is critical. Lexan resins can
be produced in a wide range of
opalescent colours with different
transmission values, as shown in

■

F I G U R E

2 3 .

4.7

Environmental resistance

4.7.1

Chemical resistance

Lexan resin can be adversely affected
by certain combinations of chemical
environment, temperature and stress.
For this reason, lubricants, gaskets,
O-rings, cleaning solvents or any
material which may come into contact
with the finished part should be
carefully evaluated for compatibility.

In all cases extensive testing of the
finished part under actual service
conditions is strongly recommended.
The performance and interpretation
of the results of end-use testing are
the end-producer’s responsibility.

While Lexan generally displays good
property retention when exposed to
water, mineral acids and organic
acids, crazing and/or embrittlement
may occur if the Lexan resin part is
highly stressed and exposed to hot
water or a humid environment.

Lexan resin is insoluble in aliphatic
hydrocarbons, ethers and alcohols.
It is partly soluble in aromatic
hydrocarbons, soluble in chlorinated
hydrocarbons and will slowly
decompose in strong alkaline
solutions.

■

TA B L E

5 (see next page)

provides a comprehensive overview of
the chemical compatibility of Lexan
resin according to the specified
GE Plastics test conditions.

L e x a n P r o f i l e 4 P r o p e r t i e s a n d D e s i g n

■

F I G U R E

2 2

Light transmission
of transparent
Lexan

Lexan

141R

non-UV stabilized

LS2

UV stabilized

OQ4320

UV stabilized with

400 nm cut-off

121R

‘infra red’ colour

ransmission (%)

Wavelength (nm)

100

300

400

500

600

700

800

900

1000 1100

visible

infra red

■

F I G U R E

2 3

Transmission of
Lexan opalescent
colours as a
function of
thickness

82025
82027
82046
82052
82062
82082
82103
82227
82253
82268

ransmission (%)

Thickness (mm)

1.5

1.8

2.1

2.4

2.7

3.0

3.3

Acid, mineral

Boric acid

Hydrogen chloride 20%

Hydrogen chloride 25%

–

Hydrogen fluoride 25%

Nitric acid 70%

–

Perchloric acid

–

Phosphorus pentoxide dry

Phosphoric acid 1%

Phosphoric acid 10%

–

Phosphorus pentachloride

Sulphuric acid 50%

Sulphuric acid 70%

–

Sulphurous acid 5%

–

Acid, organic

Acetic anhydride

–

Formic acid concentrate

–

Gallic acid

Malelc acid

Mercapto acetic acid

–

Murstic acid 20%

Muristic acid 25%

–

Olelc acid

Palmitic acid

Phenol sulphonic acid

–

Phenoxyacetic acid

Phthallic anhydride

Salycilate acid

Tannic acid

Tannic acid 20%

–

Thiodiacetic acid

Trichlor acetic acid

–

Sulphamine acid 5%

Alcohol

Allyl alcohol

–

Amyl alcohol

–

Butoxyethanol

–

Chlorethanol 2

–

Decyl alcohol

–

Dodecyl alcohol

–

Ethanol

–

Ethyl glycol 100%

–

Ethyl glycol 60%

Furfuryl alcohol

–

Glycerine

Hepthyl alcohol

–

Isobutanol

Nonyl alcohol

–

Octyl alcohol

Oxydiethanol 2.2

Phenetyl alcohol

–

Polyalkylene glycol

–

Polyethylene glycol

Propylene glycol

–

Sorbitol

Thiodiglycol 5%

–

Triethylene glycol

Tripropylene glycol

–

Aldehide

Acetaldehyde

–

Butyraldehyde

–

Formaldehyde solvent 37%

Formalin

Propionaldehyde

–

Amide

Dimethylformamide

–

Amine

Aniline

–

Diphenylamine

–

Methylaniline N

–

Methylene dianiline

–

Phenylhydrazine

–

Pyridine

–

Triethanolamine

Hydroxylamine

Base

Aluminium hydroxine powder

Ammonia concentrate

–

Ammonium hydroxide 0.13%

–

Calcium hydroxide

–

Potassium hydroxide 10%

–

Sodium hydroxide dry

Sodium hydroxide 10%

–

Sodium thotalamate

Ester

Benzyl benzoate

–

Buthyl cellosolve acetate

–

Buthyl stearate

–

Cello acetobutyrate

–

Cellulose acetate

–

Cellulose proprionate

–

Dibuthyl phthalate

–

Didecyl carbonate

–

Disodecyl phthalate

–

Disononyl phthalate

Dioctyl phtalate

–

Dioctyl sebacate

–

Ditridecyl carbonate

–

Ditridecyl phthalate

–

Ethyl bromoacetate

Ethyl butyrate

–

Ethyl cellusolve 5%

–

Ethyl chloracetate

–

Ethyl cyanoacetate

–

Ethyl lactate

–

Ethyl salicilate

–

Isopropyl myristrate

–

Methyl acetate

Methyl calicylate

–

Methylbenzoate

–

Triacetine

–

Tributoxethyl phosphate

–

Tributyl cello phosphate

–

2 dodecyl phenyl carbonate

Ether

Ether

–

Ethyl cellosolve 5%

–

Methyl cellosolve

–

Polyalkylene glycol

–

Polyethylene glycol

Polyethylene sulfide

–

Propylene oxide

–

Gaseous

Ammonia concentrate

–

Bromine

–

Chloracetophenone

–

Chlorine

–

Iodine

–

L e x a n P r o f i l e 4 P r o p e r t i e s a n d D e s i g n

This overview shows the chemical resistancy of Lexan polycarbonate
sheet. Chemical compatibility of thermoplastics e.g. Lexan is dependent
on contact time, temperature and stress (external stress to which the
application is subjected). Chemical exposure can result in discolouration,
softening, swelling, crazing, cracking or loss of properties of the
thermoplastic. The chemicals listed have been evaluated for Lexan
according to a very stringent GE Plastics test method. This test
incorporates exposure to the chemical under defined conditions including
temperature (20°C and 80°C) and stress (0.5% and 1% strain) for a time
period of seven days.
This information should be used as indicative only. The true chemical
compatibility can only be determined under conditions as in the final
application. Please contact your local representative in case additional
information is required.

■

TA B L E

Chemical compatibility of Lexan polycarbonate

Key to performance

– poor, not recommended; will result in

failure or severe degradation

0 fair, found marginal; only for short

exposures at lower temperatures or when
loss of properties is not critical

+ good; found unaffected in its performance

when exposed with regards to time,
temperature and stress according
the GE Plastics test method

Isobutane

–

Methane

–

Oxygen

Ozone 2%

–

Propylene

Sulphur dioxide

–

Sulphur hexafluoride

–

Halogenated HC

Acetylene dibromo

–

Acetylene tetrabromide

–

Bromochloromethane

–

Carbon tetrachloride

–

Chlorethanol 2

–

Chlorobenzene

–

Chlorobutane

–

Chloroform

–

Dibromomethane

–

Dichloroethane

–

Dichlorohydroxybenzene

Dichloromethane

–

Ethyl bromoacetate

Ketone

Methyl ethyl ketone

–

Metal & metal oxide

Aluminium oxide

Arsenic trioxide

–

Calcium oxide paste

–

Cuprous oxide

Mercury metallic

–

Phenol

Allyl 4 methoxyphenol

–

Cresol

–

P-Phenylphenol

–

Pentachlorophenol

–

Phenol sulphonic acid

–

Phenol 5%

–

Phenoxyacetic

Salt, inorganic

Aluminium ammonium sulphate

–

Aluminium chloride

–

Aluminium floride

Aliminium potassium sulphate

–

Aluminium sodium sulphate

Ammonium bicarbonate

Ammonium bromide

Ammonium carbonate

–

Ammonium dichromate

Ammonium persulfate

Arsenic trioxide

–

Barium carbonate

Barium chloride

Barium sulphate

Calcium carbonate paste

–

Calcium chloride

Calcium sulphate

Cesium bromide

Copper (II) chloride 5%

Iron (II) chloride

–

Iron (III) ammonium sulphate

Iron (III) chloride saturated

Iron (III) nitrate

–

Iron (III) sulphate

Lithium bromide

Lithium hydroxide powder

Magnesium bromide

Magnesium chloride

Magnesium nitrate

Magnesium sulphate

Mercury (I) nitrate

Mercury (II) chloride

–

Mono ammonium phosphate

Nickel nitrate

Potassium bicarbonate dry

Potassium bisulphate

Potassium bromate

Potassium bromide

Potassium carbonate

Potassium chlorate

Potassium chloride saturated

–

Potassium chloride 15%

Potassium chormium sulphate

–

Potassium cyanide powder

Potassiun dichromate

Potassium iodide

Potassium nitrate

Potassium permaganate

–

Potassium persulphate

Potassium sulphate

Silver chloride saturated

–

Silver nitrate

Sodium bicarbonate saturated

Sodium bicarbonate 13%

–

Sodium bisulphate

Sodium bromate

Sodium bromide

Sodium carbonate

Sodium carbonate solvent

–

Sodium chlorate

Sodium etherlaurysulphate

Sodium ferrycyanide

Sodium fluoride

Sodium hypochlorite 6%

Sodium hypochlorite 15%

–

Sodium nitrate 10%

–

Sodium perborate

Sodium phosphate

Sodium sillicate

Sodium sulphide

–

Sodium sulphite

Strontium bromide

Tin (II) chloride

Tin (IV) chloride

Titanium tetrachloride

Trisodium phosphate 5%

–

Zinc bromide

Zinc carbonate

Zinc chloride

–

Zinc oxyde

–

Zinc sulphate

Salt, organic

Alluminium acetate

Ammonium acetate

–

Ammonium oxalate

Aniline sulphate

Potassium acetate 30%

–

Qulnine sulphate

–

Sodium acetate 30%

–

Valine bromide dl

L e x a n P r o f i l e 4 P r o p e r t i e s a n d D e s i g n

4.7.2

Sterilization

Lexan polycarbonate meets the
requirements of the FDA and USP
Chapter XXII Class V1 for use in the
medical industry where it is used for a
wide range of equipment which must
be sterilized. This can be achieved by
all three commonly used methods:
gamma radiation, EtO gas and steam
(autoclave). Tailor-made Lexan GR
grades provide superior colour
stability and resistance to yellowing
following gamma or EtO sterilisation.

4.7.3

Cleaning and degreasing

Cleaning or degreasing of Lexan
resin finished parts can be performed
using methyl or isopropyl alcohol,
mild soap solutions, heptane or
hexane. The parts should not be
cleaned with partially hydrogenated
hydrocarbons, with ketones such as
MEK, with strong acids or with
alkalines such as sodium hydroxide.

4.7.4

Ultraviolet exposure

Lexan resin may be sensitive to long-
term exposure to ultraviolet light and
weathering. The degree of sensitivity
is very much dependent on the
specific grade, the specified colour
and the weathering conditions.

Lexan resins are ideally suited to a
range of both indoor and outdoor
applications.

■

F I G U R E S

2 4 and 2 5

show that UV stabilized Lexan grades
maintain high light transmission after
prolonged UV exposure and offer a
good resistance to yellowing after
prolonged exposure to harsh climatic
conditions.

L e x a n P r o f i l e 4 P r o p e r t i e s a n d D e s i g n

■

F I G U R E

2 5

Yellowness index
of transparent
Lexan after
natural exposure
acc. ASTM G7,
at Florida (USA)

ellowness index

Exposure (years)

■

F I G U R E

2 4

Transmittance
of transparent
Lexan after
natural exposure
acc. ASTM G7,
at Florida (USA)

Lexan

UV stabilized

non stabilized

Lexan

UV stabilized

non stabilized

ransmittance (%)

Exposure (years)

For applications which are exposed
to critical environments of intense
sunlight and high humidity, Lexan
resin can be additionally protected in
various ways. Tailor-made glass clear
UV cap-layers further improve the
weathering resistance of extruded
Lexan sheet, while for injection
moulded parts a variety of coatings,
including a range of GE Silicone
hardcoats, enhance weathering,
scratch and abrasion resistance.

■

F I G U R E S

2 6 and 2 7 illustrate the

enhanced resistance to haze and
yellowing which can be obtained
through the application of a silicone
hardcoat.

4.8

Processibility

To obtain extruded sheet, blow
moulded or injection moulded parts,
the material’s flow properties are
critical. These are measured based on
melt flow length and melt tempera-
ture. The flow lengths of GE Plastics

materials are given as calculated disk
flow lengths, where the injection
pressure is plotted against the radial
flow length. Determination of the
calculated disk flow length is
important when trying to predict
whether or not a part can be filled.
As an example,

■

F I G U R E

2 8 shows

the calculated disk flow lengths of
Lexan 141R.
The melt flow length of a material is a
function of viscosity, shear properties
and thermal properties.

L e x a n P r o f i l e 4 P r o p e r t i e s a n d D e s i g n

■

F I G U R E

2 6

Haze of transparent
Lexan, coated and
uncoated, after
accelerated outdoor
exposure

Lexan

uncoated

coated

Lexan

uncoated

coated

Haze (%)

Exposure (hours)

500

1000

1500

2000

■

F I G U R E

2 7

Yellowness Index
of transparent
Lexan, coated and
uncoated, after
accelerated outdoor
exposure

ellowness index

Exposure (hours)

500

1000

1500

2000

■

F I G U R E

2 8

Calculated flow
length indication
of Lexan 141R

3 mm
2 mm
1 mm

Flow length (mm)

Injection time (s)

Gate pressure (MPa)

500

400

300

200

100

120

4.8.1

Viscosity

Lexan resin is available in a wide
range of viscosities which are
obtained by producing polycarbonate
with different molecular weights:
higher molecular weight grades
have a higher viscosity.
The portfolio ranges from ultra-low
viscosity Lexan OQ grades for the
DVD format, to very high viscosity
grades for multiple wall extrusion, as
depicted in

■

F I G U R E

2 9 .

■

F I G U R E

3 0

shows the range of melt viscosities for
various glass-filled grades, while

■

F I G U R E

3 1 relates specifically to

selected flame-retarded grades.
Common viscosity tests include melt
viscosity, MV, and melt volume rate,
MVR, measurements.

4.8.2

Shear properties

MV tests are carried out over a large
range of shear rates. As materials
show significantly different MV
curves, comparisons should be made
according to the MV curves rather
than on the MVR. As can be seen in

■

F I G U R E

3 2 , Lexan resin exhibits

a very low degree of shear thinning
when compared with other
thermoplastics. Unlike most
thermoplastic materials,
polycarbonate shows an almost
Newtonian behaviour, which means
that the viscosity is hardly influenced
by the shear rate.

Shear curves showing the relationship
between shear rate and viscosity at
different temperatures are required
for accurate injection moulding
simulation.

L e x a n P r o f i l e 4 P r o p e r t i e s a n d D e s i g n

■

F I G U R E

2 9

Capillary melt
viscosity of Lexan
showing a wide
range of available
viscosities
(300°C)

Lexan

ML3021A

201R
261R
241R
221R

HF1110R

ML3729

OQ1020LN

Viscosity (Pa

·sec)

Shear rate (sec

-1

)

■

F I G U R E

3 1

Capillary melt
viscosity of
standard flame
retarded Lexan
grades (300°C)

Lexan

950

950A

940

940A

920

920A

Viscosity (Pa

·sec)

Shear rate (sec

-1

)

■

F I G U R E

3 0

Capillary melt
viscosity of
standard glass
filled Lexan
(300°C)

Lexan

3414R

40% glass filled

500R

10% glass filled

3412R

20% glass filled

Viscosity (Pa

·sec)

Shear rate (sec

-1

)

4.9

Mould shrinkage

Mould shrinkage refers to the
shrinkage that a moulded part
undergoes when it is removed
from a mould and cooled at room
temperature. Expressed as an average
percentage, mould shrinkage can
vary considerably depending on the
mould geometry, the processing
conditions and the type of resin.

As an amorphous material, Lexan
resin exhibits lower shrinkage than
semi-crystalline materials. The levels
of shrinkage in both cross-flow and
flow direction are also closer to each
other for amorphous materials, which
makes it easier to produce precise
parts. The addition of glass
reinforcement increases the degree
of orientation but lowers shrinkage.
The influence of the material on
shrinkage is usually expressed by the
PVT (Pressure-Volume-Temperature)

relationship. This relationship is
illustrated for both unreinforced and
glass-fibre reinforced Lexan grades in

■

F I G U R E

3 3 .

The packing or holding pressure
phase in the injection moulding
process also has a significant effect on
shrinkage. In general, the higher the
holding pressure and the longer it is
effective, the smaller the shrinkage.
This is illustrated in

■

F I G U R E

3 4 .

L e x a n P r o f i l e 4 P r o p e r t i e s a n d D e s i g n

■

F I G U R E

3 3

PVT relationship
for unreinforced
and glass
reinforced Lexan
(80MPa)

Lexan

141
500

3412R

Specific volume (cm

)

Temperature (°C)

1.00

0.95

0.90

0.85

0.80

0.75

0.70

120

160

200

240

280

320

360

■

F I G U R E

3 2

Melt viscosity
of polycarbonate
and most other
thermoplastics

Viscosity

Shear rate

polycarbonate

most thermoplastics

■

F I G U R E

3 4

Typical PVT
relationship
for Lexan PC.
Higher holding
pressure reduces
volumetric
shrinkage

0 MPa

50 MPa

100 MPa
150 MPa

Specific volume (m

/kg)

Temperature

150

room

freeze

Lexan polycarbonate can be
successfully processed by injection
moulding, structural foam moulding,
extrusion, injection (stretch) blow
moulding and extrusion blow
moulding. Extruded sheet from
Lexan polycarbonate resin can be
thermoformed. Standard equipment
can be used and the processing range
is very broad. Fast cycle times are
possible and any rejects can be
ground and reused, providing
contamination has not occurred
during processing.

5.1

Pre-drying

Most thermoplastic materials absorb
atmospheric moisture which, at
normal processing temperatures,
can cause polymer degradation.
This consequently lowers property
levels, in particular impact strength.
Lexan polycarbonate therefore must
be thoroughly dried before moulding
to ensure optimum part performance
and appearance. The recommended
drying temperature is 120°C; the time
required to achieve sufficient drying
is dependent on the type of dryer
and varies from 2 to 4 hours. Target
moisture content should be a
maximum of 0.02%. Excessive drying
times of over 24 hours will not affect
the properties of the polymer but
they might decrease release
performance during processing.

5.2

Equipment

High compression ratio screws
or those with a short compression
zone should not be used.
It is recommended to use a
conventional 3-zone screw with a
L:D ratio of 20:1 - 25:1 and a
compression ratio of 2:1 - 2.5:1.

Conventional construction materials
for screw and barrel are acceptable
for the processing of Lexan resin.
However, screws and cylinders of a
bimetallic type with high abrasion
and corrosion resistance are
preferred, especially for glass-filled
grades.

A vented barrel and screw is not a
satisfactory alternative to pre-drying
and is therefore not recommended
for Lexan resin. If a vented barrel is
used, then the level of moisture which
is present in the material, and the
percentage of the shot capacity,
will have a considerable influence
on whether any degradation is
encountered as a result of hydrolysis.

A free-flowing nozzle with its own
heater band and control is
recommended. Nozzle openings
have to be as large as possible.

It is possible to mould with as little as
35 N/mm

clamping force but more

commonly pressures are between
40 and 50 N/mm

. For complex thin

wall components requiring fast
injection speeds combined with high
injection pressures, a clamping force
of up to 80 N/mm

is required.

Careful attention to the right tool/
equipment combination is critical for
complex thin wall components which
require fast processing and high
injection pressures.

5.3

Processing conditions

Melt temperature

It is important not to create long
residence times which can result
in material degradation. For Lexan
resin, the ideal maximum residence
time is between 6 and 12 minutes,
depending on the selected melt
temperature. When processing
Lexan on the upper limit of the
melt temperature range, it is
recommended that the shot size
is 60% - 80% of the barrel capacity
to minimize residence time.

Back pressure

A machine back pressure of 5 - 10 bar
is recommended in order to improve
melt quality and maintain a consistent
shot size. For glass-reinforced grades,
careful monitoring of back pressure is
advisable in order to minimize fibre
damage.

Screw rotation speed

Screw surface speeds should not
exceed 250 - 300 mm/s.
For reinforced grades a screw
speedat the lower end of the range
is recommended.

Suck back

The suck back stroke should be just
enough to keep the resin in and the
air out, to avoid melt degradation
and subsequent moulding problems.

Screw cushion

A screw cushion of 3 - 10 mm is
recommended, depending on the
screw diameter. Without a cushion it
is not possible for the after pressure
to have an effect.

Injection speed

The fastest possible injection speed is
desirable due to Lexan resin’s fast set-
up times, especially when using glass-
reinforced grades. Adequate venting
is essential when selecting a fast
injection speed.

Mould temperature

Lexan resin should always be
moulded in temperature-controlled
moulds. High mould temperatures
are desirable for optimum flow,
minimum moulded-in stress and
optimal surface appearance.

5.4

Venting

Good mould venting is essential to
prevent blistering or burning and
to aid cavity filling. Ideally the vents
should be located at the end of the
material flow paths. Inadequate or
poorly located venting can result in

P r o c e s s i n g

incomplete filling, poor weld line
strength, uneven shrinkage, warping
and the need for excessive injection
pressure to fill the cavity.

5.5

Interruption of production

Keeping Lexan resin in the cylinder
overnight or over a weekend is
generally not recommended. If
production delays are unavoidable,
the following precautions are
recommended.

Reduce cylinder temperature to
170°C - 180°C

Leave heaters on

Ensure that the temperature never
drops below 160°C. This is to prevent
the resin from adhering to the
cylinder walls which may pull off
metal particles and degraded resin
as it cools and contracts, causing
black specks in the mouldings when
production is restarted

During production delays, empty the
screw to prevent overheating

5.6

Purging of the barrel

Thorough purging of the barrel is
required when changing materials.
The best purging material for Lexan
resin is PMMA. PA or ABS should not
be used as a purging material directly
after Lexan resin. The cylinder
temperature should be lowered if the
resins to be moulded afterwards are
POM, ABS or PA.

5.7

Recycling

Sprues and faulty mouldings can all
be reground with minimal reduction
in resin properties. Care must be
taken to ensure that the regrind is
free from impurities and that proper
pre-drying of the regrind has been
carried out. Blends of regrind and
virgin material are possible in the
ratio of 20:80. Regrind should not
®be used in applications where
impact performance and/or agency
compliance are required.

Note
Further information on the
processing of engineering
thermoplastics can be found
in GE Plastics brochures:

Injection Moulding Mini Guide

Engineering Thermoplastics in
the Extrusion Industry

L e x a n P r o f i l e 5 P r o c e s s i n g

Nozzle

Zone 3

Zone 2

Zone 1 Hopper

Mould

Melt temperature 280 - 310 °C

°C

350

300

250

200

150

100

■

F I G U R E

3 5

Typical moulding
temperatures
for Lexan general
purpose: 141R

Nozzle

Zone 3

Zone 2

Zone 1 Hopper

Mould

Melt temperature 280 - 300 °C

°C

350

300

250

200

150

100

■

F I G U R E

3 6

Typical moulding
temperatures
for Lexan flame
retarded: 940

Nozzle

Zone 3

Zone 2

Zone 1 Hopper

Mould

Melt temperature 290 - 320 °C

°C

350

300

250

200

150

100

■

F I G U R E

3 7

Typical moulding
temperatures
for Lexan flame
retarded, glass
filled: 500R

Although most Lexan parts are
moulded as finished components,
the design and ultimate use of
certain parts may require machining,
assembly or finishing operations.
Lexan resin makes a wide variety of
secondary operations available to the
design engineer.

6.1

Welding

Welding is a commonly used
permanent assembly technique for
engineering thermoplastics. Lexan
parts can be welded using different
processes. Selecting the right process
depends on the size, shape and
function of the part:

Hot Plate welding

allows excellent

weld strengths to be achieved at
temperatures of 260°C - 300°C

Friction welding

can be applied,

using either the vibration, orbital
or rotation method

Ultrasonic welding

is commonly

used, in particular for mobile
telephone components. Welding
amplitudes with 20 kHz ultrasonic
processes should be in the range
of 25 - 40 µm (0-peak)

Induction Welding

6.2

Adhesives

Lexan resin parts can be bonded to
other plastics, glass, aluminium, brass,
steel, wood and other materials.
A wide variety of adhesives can be
used, sometimes with the addition of
a suitable primer. In general, Lexan
parts can be easily solvent bonded to
parts made from Lexan, Cycolac

ABS

or Cycoloy

PC/ABS alloy with Methyl

Ethyl Ketone (MEK) or in mixtures
of MEK with Cyclohexanone, ideally
50:50.

Cleaning parts

Thorough cleaning of Lexan parts
before bonding is essential in order
to avoid part failure. All oil, grease,
paint, mould releases, rust oxides,
etc., must be removed by washing
with solvents which are compatible
with Lexan resin. These solvents
include isopropyl alcohol, heptane
or a light solution of non-alkaline
detergents. Bond strength is further
improved by sanding, sand blasting or
vapour blasting the bonding surfaces.

6.3

Mechanical assembly

Mechanical assembly techniques are
widely used with Lexan parts. To
achieve optimum results, mechanical
fasteners should be kept free from oil
and grease. Depending on the type of
fastener, a permanent stress or
deformation is applied locally. Clamp
forces should be controlled or
distributed over a large surface area.
This is in order to decrease local
stresses in the part after assembly and
to minimize the risk of loosening the
fasteners through creep and
relaxation. Notches in the design as
well as notches resulting from
mechanical fasteners should also be
avoided.

Recommended assembly techniques:

Thread-forming screws rather
than thread cutting screws are
recommended. Screws with a
maximum flank angle of 30° are
preferred for minimal radial stresses

Inserts which leave low residual
stresses can be used. Installation by
heat or ultrasound are the preferred
techniques. Press and expansion
inserts produce high hoop stresses in
bosses and should therefore be used
with caution

Snap fit assembly

Rivets

Staking

Note
General information on Secondary
Operations like welding, mechanical
assembly and bonding of engineering
thermoplastics can be found in the
following GE Plastics brochures:

Assembly Guide

Design Guide

S e c o n d a r y O p e r a t i o n s

Epoxy

PUR

PUR hot

Silicone

Acrylic

Cyano-

melt reactive

polymer

acrylate

primer

yes

yes/no

aggressive

at high t°

alkoxy

yes

■

TA B L E

Compatibility of adhesives with Lexan resin

6.4

Painting

A wide variety of colours and textures
can be applied to Lexan using
commercially available organic paints
and conventional application
processes. Painting is an economical
means of enhancing aesthetics and
providing colour uniformity.

Pre-treatment

Handwashing the part with cleaning
agents based on alcohol or aliphatic
hydrocarbons
or:

Powerwashing the part with cleaning
agents based on detergents dissolved
in water. These detergents can be
either acidic by nature, (pH 3 - 4),
or neutral, (pH 8 - 9). Alkaline-based
detergents (pH >11) should be
avoided.

Paint selection

Paint selection is determined by the
desired decorative effect, specific
functional needs and the application
technique to be applied. A variety of
conventional and waterborne paints
can be successfully applied to Lexan
resin. Generic types include:

Acrylic

Epoxy

Polyester

Polysiloxane

Polyurethane

Special coatings

A range of siloxane-based coatings
with inherent glass-like optical
properties has been developed to
provide Lexan resin transparent parts
with optimum chemical and scratch
resistance and UV protection. These
special coatings can be easily applied
by dip coating, flow coating or by
spraying

Acrylic-based coatings can be used in
applications such as compact discs
where only UV protection and
moderate scratch resistance is
required

Coatings can be used to help
minimize colour degradation

Conductive coatings offer shielding
against radio frequency interference
(RFI) or electromagnetic
interference (EMI)

Paint solvents

It is important that solvent
formulations are carefully considered
when selecting a paint for use with
amorphous resins such as Lexan.
It should be stressed that it can be
difficult to achieve an ideal match
between solvent and substrate.

Although it is generally difficult
to give rules for balancing solvent
mixtures, there are some basic
guidelines. For example, strong
solvent action can be balanced with
a non-dissolving liquid like butanol
or dipentene. Solvents with strong
embrittlement effects, on the other
hand, can be balanced by adding
stronger dissolving solvents. It should
be noted that lower boiling point
solvents cause embrittlement effects
more quickly.

The occurrence of stress cracking is
a result of solvent action on the one
hand and stresses in the part on the
other. The level of stress in the part
should be ideally below 5 MPa.
This is achieved through optimal part
and tool design and proper moulding
procedures. In general, if stress levels
are above 10 MPa, painting will
become critical. In case of doubt,
Lexan resin parts should be tested
using a mixture of Toluene and
n-Propanol or propylene-carbonate.

6.5

Metallisation

Properties usually associated with
metals such as reflectivity, abrasion
resistance, electrical conductivity
and decorative surfaces can be
added to plastics through
metallisation. Three of the more
commonly applied metallisation
techniques are discussed here.

Vacuum metallisation

Vacuum metallisation through
Physical Vapour Deposition involves
the depositing of an evaporated
metal, mostly aluminium, on a
substrate. To achieve evaporation,
the pure metal is heated in a deep
vacuum. To ensure a good result
when using this method with Lexan
resin, a glow discharge pre-treatment
is highly recommended.

After vacuum metallisation, the
aluminium must be protected
against environmental influences.
This is because of the ultra-thin
layer thickness combined with the
reactive nature of aluminium to
humidity. Most commonly this
protection is provided through the
application of a Plasil/Glipoxan top
layer, (a silicone-based monomer
layer which is applied in the vacuum),
or a clear coat top layer.

In general, unreinforced Lexan
resin does not require a basecoat
or lacquer primer layer before
metallisation because of the good
surface quality of Lexan parts after
moulding. However, in certain cases,
application of a basecoat is
recommended to enhance reflectivity,
in particular where a glass-filled
Lexan material has been specified.

L e x a n P r o f i l e 6 S e c o n d a r y O p e r a t i o n s

In most cases a surface activation
pre-treatment is required.

Glow discharge takes place in a
vacuum vessel in the presence of a low
pressure gas such as air. This method
gives an increased surface energy and
micro porosity to the Lexan part.

Cleaning with a cloth or solvents is
not recommended because of the
sensitivity to scratches that can be
seen after metallisation. The best
method is to keep the mouldings
clean and to metallise the parts as
soon as possible after moulding, or
to store them in clean containers.

Plating

This can be done by two methods.
In the first, electro plating, current
is used to effect an electrolytic
deposition of metals derived from a
dissolved metal salt. Most frequently
used metals include chrome, nickel
or gold.

The second method, electroless
plating, is executed without the
addition of current to the galvanic
process. Electroless plating can be
further divided into non-selective
(double-sided) and selective (single-
sided) plating.

For non-selective or all-over
electroless plating, a pre-etch is
generally required with Lexan resin.

Selective electroless plating starts with
the masking of those areas of the part
which must remain metal-free.
A catalytic lacquer is then applied to
seed the exposed surface to initiate
the deposition of metal after
immersion in the metal salt solution.

If only EMI shielding is required, an
electroless copper layer of 1 - 2 µm is
applied with a finish of electroless
nickel.

Hot foil stamping

In this dry metallisation technique,
the metal foil is impressed on the
plastic surface with a heated die or
rubber roll. Standard foils are
available for use with Lexan resin
parts, but it is recommended to test
each grade and new application for
compatibility and melting point.

6.6

Laser marking

The laser marking of thermoplastics
is a complex process. The differing
demands of applications, together
with a diverse range of materials,
pigments and additives, as well as
the equipment itself, provide a large
number of variables. Through its
advanced research and development
programme, GE Plastics has gained
valuable insight into the thermal,
optical, mechanical and chemical
processes which take place during
laser marking. An important result of
this has been the development of a
broad tailor-made range of materials
using proprietary combinations of
pigments and additives. These
include Lexan grades 121R, 141R
and ML3432 which provide light on
dark contrast laser marking.

Note
General information on Secondary
Operations like painting and
metallisation of engineering
thermoplastics can be found in the
following GE Plastics brochures:

Painting Guide

Metallization Guide

L e x a n P r o f i l e 6 S e c o n d a r y O p e r a t i o n s

GE Plastics

100

150

200°C

15000 MPa

12500

10000

7500

5000

2500

Lexan

Heat

Flammability

•

5VB

120

160

200 MPa

100 kJ/m

Modulus

Impact

Str

ength

profile

Lexan

300°C

GE Plastics in Europe

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General Electric Plastics B.V.
1 Plasticslaan, PO Box 117
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The Netherlands
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MAKING UP THE GE PLASTICS UNIT OF GENERAL ELECTRIC COMPANY*,
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WARRANTY OR GUARANTEE, EXPRESS OR IMPLIED, (I) THAT THE RESULTS
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