How To Process Solid Polycarbonate Sheets ?

We have seen more polycarbonate panels, but our understanding of the processing methods of polycarbonate panels is very little. This kind of board with excellent performance should not be simply manufactured. There are several processing techniques commonly used in polycarbonate panels processing, let's take a look!

Several processing techniques commonly used in PC polycarbonate panels processing are: polycarbonate panels cutting; polycarbonate panels engraving; polycarbonate panels bending; PC board die-cutting; polycarbonate panels stamping, etc.

1. PC sheet die-cutting: This process is suitable for simple PC sheet cutting, but the trouble is that the mold needs to be opened. This process is suitable for cutting thin PC sheets. We usually recommend customers to cut sheets of less than 1.0 mm in batches. If the polycarbonate panels is too thick, the cost of cutting or engraving with a saw blade will be much lower. It should also be noted that the customized mold cannot be used indefinitely, and the mold will become dull after a long period of die-cutting.

2. Stamping: The punching process of the punch also has restrictions on the thickness of the polycarbonate panels material. Generally, it is suitable for polycarbonate panels materials within 1.5 mm, and the quantity is relatively large. Although polycarbonate panels materials with a thickness of 2mm or even thicker can also be stamped, in order to ensure dimensional accuracy, the cutting die will be frequently replaced, which greatly increases the cost. Therefore, if the polycarbonate panels material is thin and on top of the product, if the board is not thin, please compare before choosing stamping or engraving.

3. Cutting processing: This technology is mainly for products with low processing requirements, mainly products with low precision requirements and conventional squares that do not require punching and chamfering. Generally, the cutting of sliding table serrations is now more used. Because it is a manual operation, the processing accuracy has a lot to do with the operator, and the general accuracy is controlled at about 0.5 mm. If the requirements are high, it can only be completed by CNC machining, the accuracy can be controlled at 0.02, and the edge is smooth without burrs, but the price is relatively high and the efficiency is not high, so currently single products generally choose saw tooth cutting.

4. Engraving processing: polycarbonate panels engraving is widely used. Especially after the polycarbonate panels is subdivided in the market, the shape and quality requirements of the products have been improved. Generally speaking, polycarbonate panels engraving processing can meet more needs. Many customers now think of engraving and processing polycarbonate panels first, which greatly saves costs.

5. Bending processing: There are two main types of bending: one is cold bending, generally 150 times its thickness can be used as the cold bending radius. However, for polycarbonate panels materials with anti-scratch layer, cold bending 175 times should be considered. If it is smaller, therm  forming is recommended. Cold bending will produce a certain amount of deformation, and the magnitude of the deformation depends on the thickness of the plate.

 

 

 

The process of manufacturing solid polycarbonate sheets involves several steps. Here is a detailed explanation of the process:

Material Preparation:

Polycarbonate pellets are selected as the raw material for manufacturing solid polycarbonate sheets.

The pellets are carefully inspected for quality and purity.

Any impurities or contaminants are removed to ensure the final product's integrity.

Melting and Extrusion:

The polycarbonate pellets are melted at a specific temperature to form a molten mass.

The molten polycarbonate is then extruded through a die to create a continuous sheet.

The extrusion process ensures uniform thickness and dimensions of the sheet.

Cooling and Solidification:

The extruded polycarbonate sheet is rapidly cooled using a cooling system.

The cooling process solidifies the molten polycarbonate, transforming it into a solid sheet.

The sheet is carefully monitored to ensure proper cooling and solidification.

Trimming and Cutting:

Once the polycarbonate sheet is fully solidified, it is trimmed to remove any excess material or irregularities.

The sheet is cut into desired sizes and shapes using cutting tools or machinery.

The cutting process ensures that the final product meets the required specifications.

Quality Control:

The manufactured polycarbonate sheets undergo rigorous quality control checks.

Various tests are conducted to ensure the sheets meet the required standards for strength, durability, and transparency.

Any defective sheets are identified and removed from the production line.

Packaging and Storage:

The finished polycarbonate sheets are carefully packaged to protect them from damage during transportation and storage.

Proper labeling and documentation are done.