FUNCTIONAL FORMS

LEXAN SHEET ™

PROCESSING GUIDE
FORMING, FABRICATING, FINISHING AND DECORATING
SOLID UN-COATED AND COATED SHEET
Index

INTRODUCTION 3

FORMING 4

PRE-DRYING 5
THERMOFORMING TECHNIQUES 5
HEATING AND COOLING 7
DRAPE FORMING 8
PRESSURE FORMING 9
TWIN SHEET FORMING 10
PRODUCT DESIGN 11
MOLDS AND MOLD DESIGN 13
DOMES AND PYRAMIDS 14
HOT LINE BENDING 14
COLD CURVING 15
COLD LINE BENDING 16

FABRICATING 17

TECHNIQUES 17
DRILLING 18
MILLING 19
MECHANICAL FASTENING DEVICES 19
RIVETING SYSTEMS 21
MISCELLANEOUS FABRICATING TECHNIQUES 21

FINISHING, DECORATING AND CLEANING 23

CHEMICAL RESISTANCE 23
CLEANING RECOMMENDATIONS 24
PAINTING 25
SCREEN PRINTING 25
ANTI-STATIC TREATMENT 26
ADHESIVES AND SEALANTS 26
JOINT DESIGN CONFIGURATIONS 27

CONTACT US 28

2
Introduction

Forming
From high speed trains to street furniture, and from snowmobiles to motorway signs, LEXAN™ sheet products are
designed and manufactured in a diverse range of shapes and sizes. One of the most common methods of producing
these parts is thermoforming. Thermoforming LEXAN sheet, a polycarbonate material, is a manufacturing process
where a plastic sheet is heated to its softening temperature, formed to a specific shape in or over a mold by using
vacuum, and trimmed to create a usable product. Today, thermoforming can offer many benefits over other
thermoplastics processes as well as other traditional materials like steel and glass reinforced plastics. The thermoforming
process requires a relatively low level of forming pressure, so tooling can be constructed less expensively than tooling
used in other processes. Depending on the part size, shape, and quantity, thermoforming can be an efficient and very
cost-effective production process for many plastic parts. Tooling can be produced in a very short timeframe relative to
other plastic processes and may provide faster production for large volume runs compared to rotationally molded or
fiberglass reinforced plastic processes; resulting in quicker time to market.

Next to providing an excellent part volume/quality ratio, thermoforming process enables freedom of design and
addition of small details in the part. Also pre-colored thermoplastic sheet can give the final part a good surface finish,
which can eliminate the need for painting.

By using LEXAN EXELL™ D and LEXAN XL grades, you can enhance your design opportunities with a UV‑resistant surface
while thermoforming your product.

There are various steps involved in thermoforming including design, processing, production, and finishing. We
recommend designers to contacts us before tooling. To assist designers and converters with the selection of a
production method, in the following section, we have outlined some of the design and manufacturing techniques that
are used for thermoforming of LEXAN sheet.

3
Forming

TABLE 1
FORMABILITY
Hot Cold
Vacuum Drape Twin sheet Pressure Cold Flat Curved
Sheet Materials forming# forming forming# forming*
line line
curving lamination lamination
bending** bending**
LEXAN™ 9030 / 9030 TG

LEXAN ULG1003

MARGARD™ MR5E

MARGARD HLG5

MARGARD HLGA2

MARGARD MR5 IR

MARGARD FMR

MARGARD FLG5 XT

LEXAN EXELL™ D

LEXAN EXELL D SC IR

LEXAN EXELL D ST

Sign grades
MARGARD CTGXT /
CTGXT AF
FR grades

GEPAX™

ULTEM™

#
Transparent sheet in contact with mold surface can cause haze and an optically distorted surface.
** The mar resistant or U.V. protected surfaces can be damaged around the bent area during the bending process.

4
Forming

PRE-DRYING TABLE 2
The majority of thermoplastic resins, including sheet RECOMMENDED DRYING TIMES
products, are hygroscopic, which means that they
Sheet Thickness (mm) Drying Time (hrs)
absorb moisture. Moisture builds up in the polymer sheet
during manufacturing, transportation and storage. When 0.375 0.15
sheet material comes out of the extrusion, it presents no 0.50 0.25
problem. However, during forming, excess moisture can 0.75 0.50
cause bubbling and other surface appearance problems
as well as a reduction in property performance. 1.00 2.00
1.50 3.00
Trapped moisture forms vapor above 120 °C and 2.00 4.00
the vapor expansion creates bubbles in the sheet. It is
essential that moisture in the sheet is removed prior 3.00 6.00
to forming. Standard PC sheets should be placed in 4.00 8.00
a dehumidifying air circulating oven for pre-drying, 5.00 10.00
with approximately 10-25 mm. separation between
sheets. Oven temperature should be at 120°C and 6.00 12.00
monitored with controls. Polycarbonate sheet begins 8.00 16.00
absorbing moisture immediately upon removal from the
pre-drying oven. The rate of absorption is dependent THERMOFORMING TECHNIQUES
upon the ambient dew point. For this reason, it is LEXAN™ sheet, a polycarbonate product, can be
crucial to transfer the sheet directly to the forming thermoformed into a wide variety of applications. The
machine as quickly as possible. To avoid warpage, basic steps involve the heating, shaping and cooling of
drying temperatures should not exceed 125 °C and a thermoplastic sheet product. There are a number of
the air volume in the oven should be changed six times different forming techniques, some of which only require
per hour to allow for the removal of water vapour. For heating to allow the sheet to conform to a simple
specifics PC sheet grades, please check the product positive or negative mold as in drape forming. Others,
datasheet for drying temperature advise. such as vacuum and pressure forming require that, after
heating, the sheet is formed to conform to a mold by
Before starting the drying process, masking on the applying pressure or a vacuum.
sheet materials should be removed. After removing
the protective masking, the sheets should be hung While each thermoforming process is slightly different,
vertically in the air-circulating drying oven or placed as illustrated in Figures 1 and 2, the basic steps are very
in a circulation oven and pre-dried according to the similar. Vacuum forming, pressure forming, and line
recommendations outlined in Table 2. Alternatively, bending are the mostly used processes.
the sheets can be placed in racks with a separation
of approximately 1.0 to 2.5 cm between the sheets. Pressure forming is a type of thermoforming process and
Following pre-drying the sheet should be processed pressure is applied to the positive side of the mold to
within a few hours. The time limit depends upon the wall reproduce detailed mold features. The sheet is cooled,
thickness and local environmental conditions. Generally, the mold moved downwards, and the product taken out
2 hours drying time per mm. thickness of the sheet at of the machine. The clamping edges are removed from
120 °C is recommended. the product and it's ready for trimming to finish the
product.
Do not expose the sheet to prolonged drying times at
elevated temperature. Continuous exposure beyond As a manufacturing process, the technique offers
24-30 hours can reduce the physical performance of the significant advantages and is widely used for its
LEXAN sheet and cause discoloration. simplicity and low production costs. Note, however, that
LEXAN™ MARGARD™ sheet cannot be thermoformed
because of its protective coatings.

The major benefits of thermoforming are listed below:

• Medium to large part production
• Short lead times
• Low tooling cost versus injection molding

5
Forming

FIGURE 1
POSITIVE FORMING AND NEGATIVE FORMING
POSITIVE FORMING NEGATIVE FORMING
Heater

Material

Mold

Vacuum Line

Product

FIGURE 2
BUBBLE FORMING AND PLUG-ASSISTED FORMING

Heater (Double Sided)

Material

Mold

Bubble Blowing

Plug Down
Mold Up

Final Forming

6
Forming

HEATING AND COOLING Optimum forming conditions depend upon part design,
HEATING draw ratio, sheet thickness and the forming technique
Controlled and uniform heating of LEXAN™ sheet, a employed.
polycarbonate material, is a critical factor in the
production of good quality thermoformed parts. COOLING
Sandwich type heaters are recommended as they Cooling times are dependent upon a number of factors.
provide slow even heat on both sides of the sheet. These These include ambient, forming and mold temperatures,
may be of the ceramic, halogen heating or quartz mold material, cooling system, part thickness and design
infra-red type. Proportional timers, together with a geometry. However, since LEXAN sheet materials have a
controlled heating rate are recommended, and attention relatively high heat distortion temperature, formed parts
should be paid to the influence of power variations and can be removed from the mold at around 125 °C.
air draughts. Forced water cooling is not recommended because of
the risk of building and increasing stress level in the
Slow heating rates will balance out hot spots and allow material.
the sheet edges to reach the required forming
temperature. Pre-heating of the clamping frame to
120 °C-130 °C is recommended. Since LEXAN sheet
cools rapidly, it is essential that final control and heating
is carried out on the forming machine itself. Normal
sheet temperatures are in the process window of
170 °C-225 °C for vacuum forming.

FIGURE 3
SANDWICH HEATING
Clamping Frame

Heat Source

Heat Source

Sheet

7
Forming

DRAPE FORMING FIGURE 4

Drape forming is the simplest of all the TYPICAL DRAPE FORMING SET-UP
thermoforming techniques. Using either a
male or a female mold, the sheet is heated and
allowed to conform to the shape of the mold
under its own weight or with slight mechanical
pressure.

The process involves placing the sheet (without

the masking) and mold in a hot-air circulating
oven. The temperature is raised to the point
where the sheet sags (between 140 °C-155 °C)
and conforms to the shape of the mold. Both
items can then be removed from the oven
and allowed to cool. Figure 4 illustrates the
basic steps. Exceeding the glass transition
point of LEXAN™ sheet materials will result in a
decreased optical quality.

The drape forming process can be a

combination of different methods. These
include:
• Shaping under its own weight at a
temperature of ±155 °C.
• Shaping under its own weight with a slight
mechanical pressure. (Temp. 155 °C)
• Cold curving into a jig and placing in an oven
at temperatures between 150 °C-165 °C.
• Cold curving the sheet over a mold, exposure
to a temperature of ±150 °C and application
of vacuum to obtain a 3D shape.

Cold curving guide-lines must be strictly

followed, to help avoid surface cracking of
coated products. Always allow for slow and
unforced cooling. When shaping is carried out
under the sheet’s own weight, use oversized
sheets in order to avoid material shrinkage
problems. Alternatively, the sheets can be
placed in the oven with the mold directly
outside. Once the sheet has reached the
required temperature, it should be quickly
removed and allowed to drape itself over the
mold. The transition between the oven and
the mold should be handled very fast since the
LEXAN sheet sets-up rapidly once it has been
removed from the oven. Typical applications
include visors and automotive safety glazing
where the LEXAN sheet products can meet
demanding quality requirements. In these types
of applications the mold should be made from
a high gloss material such as steel, aluminium,
or even glass in order to achieve the necessary
optical quality.

8
Forming

PRESSURE FORMING FIGURE 5

Pressure forming is similar to vacuum forming. PRESSURE FORMING
However, during the final forming stage, Pressure Chamber
Pressure
Pressure Chamber
compressed air is applied to the positive side of Chamber
Pressure Chamber
Pressure Chamber
the mold to force the sheet to conform more Heater (Double-sided
Heater (Double-sided
closely to the mold. The result is a component Heater
Heater
Heater (Double-sided
(Double-Sided)
(Double-sided
Material
with sharp features and detailed geometry. Material
Material
Material Material
Pressure Chamber
The basic steps are illustrated in Figure 5, Pressure Chamber
Pressure Chamber
Chamber
Pressure
Pressure Chamber
showing the pressure chamber mounted above Pressure Chamber
Pressure Chamber
Pressure Chamber
Pressure Chamber
Pressure Chamber
the mold. High detailed, textured surfaces and Pressure Chamber

small radii are typical of the fine detail which

can be achieved with this process.

Bubble Blowing
Bubble Blowing
Bubble Blowing
Bubble Blowing
Bubble Blowing

Maximum
Bubble height
Maximum
Maximum
Bubble
Maximumheight
Maximum
Bubble height
Bubble height
Bubble height

Mould Moving
Mould
up Moving
Pressure
Mould Moving
up Mold
Mould Moving
Moving
Pressure
Chamber
up
up up down
Pressure
Pressure
Pressure
Chamber
Chamber down
down
Chamber
Chamber downdown

Air Pressure Applied

AirPressure
Air
Air PressureApplied
Pressure Applied
Applied
Air Pressure Applied
Final Forming
Final Forming
Final Forming
Forming
Final
Final Forming

Vacuum Applied
Vacuum Applied
Vacuum
Vacuum Applied
Applied
Vacuum Applied

9
 Female mould
upper half

Forming Two sheets

heated
Sandwich
Female mould
heating
upper half

Two sheets Female mould

Sandwich
TWIN SHEET FORMING FIGURE 6
heated lower halfheating
Female mould
Twin sheet forming is a development of vacuum forming TWIN SHEET FORMING upper half

technology whereby two sheets are formed at the same Two sheets
Female mould
Sandwich
lower half
time producing an application with a hollow sealed section. heated heating
Female
Female mold
mould
upper half
upper half
The basic steps in the process are outlined in Figure 6. Female mould
lower half
Accurate temperature control is an essential element when Two
Two sheets
sheets Sandwich
Sandwich
using this technique since only one side of the sheet is heated
heated heating
heating
Vacuum on
heated. The ability to control heating in individual areas of Female mold
Female mould
the sheet is vital. Photocells also need to be installed to lower
lower half
half
control sagging and hot-air is often used to keep the two Vacuum on
sheets from touching each other. As a highly competitive
process for producing hollow sectioned parts, this method
is useful for the production of large applications. These Vacuum onSheets formed
Vacuum onagainst mould
typically include luggage boxes, air ducts, roof domes and
roof hatches.
Vacuum onSheets formed
against mould
The connection joint between the two parts is obtained by Vacuum on
a combination of melting of the two materials and the Vacuum onSheets formed
Sheets formed
exposed pressure of the molds. No additional glue or other against
againstmould
mold
adhesive is therefore necessary. This method can be used to
produce parts consisting of two materials, colours and Vacuum on
Vacuum on
gauges. Vacuum onSheets formed
against mould

Vacuum on
Vacuum on
Vacuum on

Sheets formed
Air pressure Vacuum onagainst mould
through needle
with air pressure

Air pressure
Sheets
Vacuum onSheets formed
formed
Air pressure against
against mould
mold
through needle
through needle with air pressure
Vacuum on with air pressure
Vacuum on
Air pressure Vacuum onSheets formed
against mould
through needle
with air pressure

Vacuum on

Sheets formed
Air pressure
against mould
through needle
with air pressure

Vacuum on
Formed
Formed
hollow
hollowpart
part

Formed
hollow part

Formed
hollow part

Formed
hollow part

10
Forming

FIGURE 7 PRODUCT DESIGN

BLANK SIZE DETERMINATION Major factors that affect thermoforming product design
fall into four main categories: function, economics,
L aesthetics and manufacturing. The first three of these
are largely dependent upon the actual product.
However, within the manufacturing area, certain
limitations are imposed by the nature of the process. To
assist the designer and the producer in the design
W T
process, some key factors affecting manufacturing are as
follows.

PRODUCT GEOMETRY
The component’s geometry determines the degree of
T
L sheet stretching which, in turn, is a function of the draw
ratio. The draw ratio is the difference between the
surface area of the thermoformed product (S) and the
available sheet surface inside the clamping frame (s). (See
Figure 7)

H Draw ratio (QS ) = S / s

=LW + 2LH + 2WH
W
LW

A similar relationship also exists between the sheet

thickness and the average product thickness.

FIGURE 8 QT = T / T’
BLANK SIZE REQUIRED FOR FORMING
If the component is long and slender, stretching may be
unidirectional causing excessive thinning in certain areas.
In these cases it is recommended that the depth of
20˚
20° 20˚
20°
Mould
Mold
drawing be limited to a value equal to the smallest width
of the product. For vacuum formed products, a draw
ratio of 3:1 is commonly used as a maximum. In some
Heated Area situation, higher draw ratio can be obtained based on
Heated Area
the part geometry. The above recommendations assume
an even thickness distribution throughout the part, with
SheetSize
Sheet Size a more or less symmetrical part geometry.
Heated Area + 2 x 15 mm for clamping

Heated Area + 2 x 15 mm for clamping

11
Forming

PRODUCT RADII FIGURE 9

With positive forming, geometry changes MINIMUM RADII RECOMMENDATIONS
should be accompanied by a generous
radii. With negative forming, small radii
can be achieved. The basic criterion is
that all radii should be at least equal to
the wall thickness. General guidelines are
TT
illustrated in Figure 9. Rp ≥ 2T
Rp≥2T

DRAFT ANGLES
LEXAN™ sheet products, in common with
other thermoplastic materials, shrink
upon cooling. It is therefore essential that
all surfaces should be given adequate Tmin
Tmin Rn ≥ 4Tmin
Rn≥4Tmin
draft angles to ensure easy release of the
part from the mold. For positive molds a
minimum of 2° to 3° is recommended.
However, 5° to 7° is preferable when part
geometry allows. For negative forming
0.5° to 1° is a recommended minimum.
If, however, the mold is textured, a
minimum of 2° to 3° is advised. To avoid
stress build-up and difficult removal
through post mold shrinkage, removal of Tmin Rs ≥ 10Tmin
the part made from LEXAN sheet should Tmin Rs≥10Tmin
take place at a part temperature of
120 °C.

UNDERCUTS FIGURE 10
Undercuts are possible with vacuum TYPICAL UNDERCUT DESIGN
forming. However, this often makes the
molds more complex and the processing
more critical. Undercuts are more
common in negative forming and the
simplest method is to use a loose,
removable part in the mold. A typical
example is that of a rim around the
circumference of the part as shown in
Figure 10. The loose part can be a ring in
two or more pieces that is removed from
the part once it is formed. This method of
producing an undercut is labour intensive
and will increase the cycle time. For large
series, moving parts can be installed into
the mold activated by both pneumatic
and hydraulic cylinders.

12
Forming

FIGURE 11 MOLDS AND MOLD DESIGN

VACUUM HOLE RECOMMENDATIONS Molds used for forming LEXAN™ sheet products are
relatively inexpensive and can be made from a variety of
øø0.5-0.75
0.5-0.75mmmm
different materials. Depending upon the number of
production parts required and their quality, molds can
be made from wood, polyurethane foam, epoxy resins,
metal-filled polyester, metals or 3D printed molds.. Since
they only need to withstand atmospheric pressure, there
is little wear and the flow of the plastic against the mold
surface is minimal.

While using wooden molds for prototypes and small

series production has significant advantages in terms of
availability and ease of processing, however it does have
FIGURE 12 disadvantages. Wooden molds are not dimensionally
SLOT DESIGN RECOMMENDATIONS stable, particularly at high forming temperatures, and
Mold
Mould
often with large moldings the release pressure can
damage the mold surface. For medium to large
production runs, it's recommended to use cold curing
epoxies or acrylics, or materials filled with aluminium. In
0.3-0.5 mm
0.3-0.5 mm these cases it may be necessary to provide cooling
channels in the mold to conduct away the heat build-up.
It is essential for part consistency that the mold
temperature is kept constant during forming.
Baseplate
plate Spacing
Base Spacing
Washers SHRINKAGE
Washers
The mold shrinkage should be a design consideration
when constructing the mold. The heating/cooling cycle
and the type of forming equipment will also influence
results. To allow for post forming shrinkage, for standard
polycarbonate grades, 0.6-0.7% should be added to all
dimensions with a heated mold of 120 °C. For specific
products, please check the product data sheet for the
possible shrinkage information about that material.

VACUUM HOLES
The evacuation of air pressure from the mold needs to
be achieved as quickly as possible. However, the vacuum
holes should not be so large as to leave witness marks on
the product after forming. To avoid significant marks on
the molding, 0.5‑0.75 mm diameter holes are
recommended. The holes can be recessed on the
underside of the mold to improve evacuation, as
illustrated in Figure 11. Figure 12 illustrates the spacer
and slot design.

13
Forming

DOMES AND PYRAMIDS FIGURE 13

Domes are among the simplest applications made by the FREE-BLOWN DOMES
thermoforming process. The technique involves
clamping the edges of the sheet and, after heating,
applying gentle pressure to the underside. The sheet
then stretches like an elastic membrane to form the
dome. With accurate pressure control, the shape is
maintained until the sheet has cooled. The basic steps in
the process are illustrated in Figure 13. Taking the
process one step further, pyramids can be produced, as
shown in Figure 14. A simple wooden skeleton acts as a
mold and, after applying the pressure, the mold is raised
and the sheet allowed to cool on the mold. Contact with Air
the mold is limited to the edges of the pyramid and Air Air
optical quality parts can be produced. Recommended
processing temperatures are between 170 °C-180 °C.

HOT LINE BENDING

Hot line bending is a process involving the application of
heat to the bending zone to enable thicker sheets and Air Air
more acute angles to be formed. The sheet is heated
locally along the line of the bend using a radiation
heater, typically an electrical resistance heater.
Air
Depending upon the set-up, the sheet can Airbe heated Air
from one or two sides. In the case of single side heating,
the sheet needs to be turned several times to achieve
optimum heating. The protective masking can be left on Final part
the sheet during the hot line bending process. When the
sheet has reached a temperature 155 °C-165 °C, sheet
can be bent to the required angle. For close tolerances
and/or high volume production, the use of a bending Final Part
machine equipped with temperature controlled heaters
on both sides is recommended. A typical set-up is Final part
illustrated in Figure 15. Since the process involves
localised heating, the expansion characteristics of the
sheet are not entirely predictable. For sheet widths of up
to 1m, the bend line is usually straight.
Final part FIGURE 14
For sheet widths greater than 1 m however, the line of TYPICAL PYRAMID FORMATION
the bend is often concave with the outer edges lifting, as
shown in Figure 16. Simple jigs can be constructed to
allow the sheet to cool in position which reduces the Mould
Mold
degree of distortion. In all cases it is recommended that
prototype parts are produced to determine the
feasibility of the bending operation.
Final part
This technique involves placing the sheet under stress.
However, provided certain precautions are taken, the
performance characteristics of the sheet will likely
remain unchanged.

Mould
Final Part

Final part

14
Forming

COLD CURVING TABLE 3A

This technique simply involves installing a curved sheet, MINIMUM COLD CURVING RADII
thereby placing a slight bending stress across the sheet.
LEXAN EXELL D
The stress levels in the curve are a function of sheet Uncoated LEXAN
Sheet Thickness Sheet
thickness and radii. It is recommended not to exceed (mm) Min. Radius
Sheet Min. Rad.
maximum sheet thickness and radii, to prevent any (mm)
(mm)
influence of stress on the product property performance.
The basic criteria for the minimum radii is 100 times 1.0 - 100
sheet thickness for uncoated LEXAN™ sheet products, 1.5 - 150
175 times sheet thickness for LEXAN EXELL™ D sheet and 2.0 350 200
300 times the sheet thickness for LEXAN™ MARGARD™
3.0 525 300
FMR sheet. Table 3a outlines the recommended radii for
a range of sheet thicknesses. 4.0 700 400
5.0 875 500
This technique is not recommended for mar-resistant,
6.0 1050 600
hard coated sheets such as LEXAN MARGARD MR5E
sheet. As combinations of high stress and unfavourable 8.0 1400 800
chemical conditions can lead to environmental stress- 9.5
cracking in the contact areas. It is essential that all 12
materials are checked for chemical compatibility prior to
installation. Curving formable hard coated products such 15
as LEXAN MARGARD CTG, FMR5XT sheet series and
uncoated LEXAN sheet materials prior to the drape TABLE 3B
forming process, may be done at radii 100 times to the MINIMUM COLD CURVING RADII
sheet thickness.
LEXAN MARGARD Sheet
Sheet Thickness (mm) CTG/FMR5XT Min. Radii
(mm)
FIGURE 15 2 600
TYPICAL SET-UP FOR A BENDING MACHINE 3 900
EQUIPPED WITH TEMPERATURE CONTROLLED
HEATERS ON BOTH SIDES 4 1200
5 1500
Top clamping
Top clamping
frame pivoted 6 1800
frame pivoted
8 2400
LEXAN sheet
LEXAN Sheet

FIGURE 16
EXAMPLE OF CONCAVE (BANANA) EFFECT
AFTER HOT LINE BENDING

Hotwire
Hot wire
heating element
heating element

Bottom clamping frame Support

Support
Bottom clamping frame
framework
framework
with cooling
with cooling channels
channels

15
Forming

COLD LINE BENDING FIGURE 17

Cold line bending is another forming technique for LEXAN™ sheet COLD LINE BENDING
products. Due to ductile nature of polycarbonate material, this forming
technique can be performed even at room temperatures. However, the
process does involve some degree of permanent plastic deformation and
the results can be influenced by sheet thickness, tooling and the angle of
strain bending.

A typical cold line bending operation is illustrated in Figure 17.

RECOMMENDATIONS FOR COLD LINE BENDING

• Use sharp tool edges.
• Allow sufficient time for sheet relaxation after bending (± 1-2 days).
• Do not reduce bending angle during installation or force the sheet into
the desired position.
• Due to stress relaxation immediately following bending, overbending
is usually required to achieve the desired angle.
• Coloured sheets can show tint variations along the bend following
bending.

Smooth and notch-free edges (rounded and/or 45° tapered edges) of

the LEXAN sheet are necessary to avoid-side cracking during bending. In
order to limit the critical elastic strain, cold line bending is usually
restricted to an angle of 90°. Cold line bending of LEXAN sheet FR grades
is limited because of the decreased notched impact of these materials.
Following bending, residual stresses will remain in the sheet and will
reduce the impact strength of the material in the area along the bend.
This technique should therefore be limited to less impact strength
demanding applications. We recommend not to use hard coated
materials such as LEXAN™ MARGARD™ MR5E and FMR sheet and UV
resistant sheet grades such as LEXAN EXELL™ D sheet due to the fact that
the mar resistant coating or UV protected surface can be damaged
around the bent area during the bending process. For more information
on any of the forming techniques please contact your local service team
of SABIC. Cold line bending of FR sheet grades should be considered
carefully because of the decreased notch impact effect of the process on
the material.

16
Fabricating

FABRICATING TECHNIQUES • Tungsten carbide tipped saw blades are preferred with
Fabrication can be defined as the construction, alternative teeth bevelled at 45° on both sides to
manufacture or assembly of a number of related improve cutting and reduce side pressure.
component parts. Examples of fabricating LEXAN™ sheet • Always use a low feed to get a clean cut.
products include the construction of window panels, the • Always start cutting with the blade at full speed.
manufacture of a large motorway sign or the assembly of • For single sheets less than 3 mm thick, bandsaws or jig
a safety shield around a piece of machinery. In one way saws are preferred to circular saws.
or another each of these applications requires
fabrication. The following section discusses the BANDSAWS
techniques and processes used to fabricate finished These can be of the conventional vertical type or the
products from LEXAN sheet and provides specially developed horizontal type that are made for
recommendations and advice to help maximize results. cutting plastic sheet materials. In both cases it is vital
that the sheet is adequately supported and clamped
CUTTING AND SAWING during the cutting operation. The saw guides should be
LEXAN sheet products can be cut and sawn accurately as close to the sheet as possible to reduce blade twist
using standard workshop equipment. Circular saws, band and off-line cutting.
saws, jig saws and common hacksaws can all be used
successfully. However, certain important guide-lines JIG SAWS AND HACKSAWS
should be followed. General guide‑lines are listed below An important consideration with this type of cutting is
with specific recommendations outlined in each cutting support and clamping, particularly with the use of a jig
section. saw. Blades having a tooth spacing of 2-2.5 mm are
recommended with the emphasis upon low cutting
CAUTION should be taken and required safety feeds.
equipment should be worn when cutting and sawing.
When working with thermoplastics sheet, always GUILLOTINE SAW
consider safe and careful handling. Please keep in mind Can be used on non-FR type sheets.
that plastics will lose heat more slowly than metals. Avoid
localized overheating. The method and the purpose that TABLE 4
you choose to utilize our products are beyond our
control. Therefore, it is imperative that you test our GENERAL CUTTING AND SAWING
products to determine to your own satisfaction whether RECOMMENDATIONS
our products, technical assistance and information are Circular Saw Bandsaw
suitable for your intended use and application. This Clearance Angle 20°-30° 20°-30°
application-specific test must at least include analysis to
determine suitability from a technical as well as health, Rake Angle 5-15° 0-5°
safety, and environmental standpoint. Such testing has 1800-2400
Rotation Speed 600-1000 m/min
not necessarily been done by SABIC. For further m/min
assistance and recommendations, please contact SABIC’s Tooth Spacing 9-15 mm 1.5-4 mm
Functional Forms business that you can find the
contact details on the back page of this brochure.

• The sheet must always be securely clamped to avoid

undesirable vibration and rough cut edges.
• All tools should be set for cutting plastics with fine
toothed panel blades.
• The protective masking should be left on the sheet to
prevent scratching and other surface damage.
• When finishing the edges of all LEXAN sheets,
materials should be clean and free of notches.
• If possible, swarf and dust build-up should be blown
away with a compressed air supply.

CIRCULAR SAWS
This type of cutting operation is the most common and,
it is important to follow the recommended guide-lines
for speeds and feeds.

17
 Fabricating

FIGURE 18 DRILLING
TUNGSTEN CARBIDE TIPPED SAW BLADES Standard high speed steel twist drills or drills with an angular wedged bit
USED FOR CIRCULAR SAWS can be used for drilling LEXAN™ sheet products. Carbide-tipped drills can
also be used since they retain their sharp cutting edge. One of the most
important factor to consider when drilling LEXAN sheet products is the
heat generation during the actual process. In order to produce a clean,
well-finished hole that is stress-free, the heat generation must be kept to
an absolute minimum. By following a few basic guide-lines, clean,
stress-free holes can be produced.

Angle
Angle of hookof(roke)hook (roke) • The drill hole must be cleared frequently to prevent swarf build-up
and excessive frictional heat.
3˚ positive to
3° positive to 3° negative
3˚ negative

Details of a typical saw:

Diameter 400 mm
• The drill must be raised from the hole frequently and cooled with
A tungsten carbide tipped saw blade
suitable for cutting LEXAN sheet
Tooth spacing
Gullet depth
12 mm
11 mm compressed air.
• The sheet or product must be adequately clamped and supported to
Shaft speed 4000 rev/min

Tooth spacing
reduce vibration and ensure a correctly sized hole.
• Holes should not be drilled closer to the edge of the sheet than 1-1.5
times the diameter of the hole.
• All holes must be larger than the bolt, screw or fixing to allow for
thermal expansion and contraction.
Angle of hook (roke)
gullet
depth
• For long production runs the use of carbide-tipped twist drills is
Details of a typical saw:
3˚ positive toClearance angle 25˚
3˚ negative recommended.
Diameter Details of a typical
400 saw:
mm • Select the drill bit that matches the size hole you want to drill.
Tooth spacing
Tooth spacing12 12 mm • Adjust the drill press’ speed according to your drill press operator’s
Diameter 400 mm
de tipped saw blade mm
ng LEXAN sheet Gullet depth 11 mm

Gullet depthShaft speed

11 4000mm rev/min
manual.
Tooth spacing
Shaft speed 4000 rev/min • Maintain drill feed pressure sufficient to form a continuous spiral-
Angle of hook (roke)
3˚ positive to
3˚ negative
shaped chip. This chip forms as the drill advances through the
polycarbonate sheet material. Use air or water for a coolant if the drill
A tungsten carbide tipped
saw blade canb be used
A tungsten carbide tipped saw blade
Details of a typical saw:
Diameter
Tooth spacing
400 mm
12 mm
bit becomes hot enough to melt, rather than cut, the polycarbonate.
suitable for cutting LEXAN sheet

for cutting LEXAN sheet

Gullet depth
Shaft speed
11 mm
4000 rev/min • Do not use oil or cooling fluid for drilling
gullet
depth
Tooth spacing
Tooth spacing
Drilling feeds and speeds are outlined in Table 5 with the various drill
configurations in Figures 20 to 11.

TABLE 5
Gullet
depth
gullet
FRONT VIEW DRILL BIT
depth
Clearance angle 25°
Clearance angle 25˚

Speed Feed
Hole Diameter
(rev/min) (mm/min)
3 1750 125
6 1500 100
FIGURE 19
GUILLOTINE SAW 9 1000 75
12 650 50
18 350 25

RECOMMENDED DRILL ANGLES

Chisel Cutting
Chisel Cutting
edge edges
edges
edge
angle
angle
130˚
130­°

End View
end view
Recommended drill angles:
BB
Clearance Angle A 15°
Rake Angle B 0°-5° A A
Included Tip Angle C 120°-160°
Helix Angle D 30°

18

Chisel edge
 end view

Fabricating A

TABLE 6
FIGURE 20
MILLING RECOMMENDATIONS
TYPICAL DRILL CONFIGURATION
Clearance Angle 5°-10°
Rake Angle 0°-10°
Cutting Speed 100-500 m/min
Chisel edge
Chisel Edge
Cutting Feed 0.1-0.5 mm/rev.
Cutting
edges
Cutting 90˚ FIGURE 23
having
edges
zero roke
having Parallel to surface
parallel to surface SINGLE FLUTE SPIRAL CUTTER
zero roke to to
bebe
cutcut
parallel to
Parallel to
cutting
cuttingedge
edge
FIGURE 21
TWO OR FOUR DRILL FOR LARGE HOLES

MECHANICAL FASTENING DEVICES

With a few exceptions, all mechanical assembly techniques
involve some form of additional fastening device. The choice
of device is often dependent upon the nature of the fastening
required. While rivets tend to be permanent, screws and nuts
can be made detachable and some of the spring clips types
can be either permanent or separable.
FIGURE 22
D RILL BITS FOR THIN SHEET There are many different types of mechanical fastening
systems which can be used successfully to assemble plastic
sheet components. Within the limitations of this publication
only a small number can be discussed.

For simplicity they are divided into three groups:

• Screws, nuts and bolts
• Rivets
Point angle • Spring clips and other fastening devices
wrong (or included angle) right way
Point angle
Wrong (or included angle) Correct Two important factors need to be considered with all these
fastening systems. Firstly, allowance needs to be made for
REMARK: thermal expansion and contraction. All holes, slots and
Please consult equipment supplier for drilling, cutting, cooling cut-outs must be machined over-size to allow for the
fluids, which are recommended for polycarbonate dimensional changes as a result of temperature changes.
Secondly, the distribution of tightening torque should be
MILING equal. With the aid of compatible rubber washers and large
LEXAN™ sheet products can be machined using conventional screw and rivet heads, the tightening torque should be spread
milling machines fitted with standard high speed knife cutting over as wide an area as possible and should not be excessive.
tools. Once again the importance of suitable clamping cannot
be over-emphasised. Mechanical jigs and fixtures, or vacuum TABLE 7
chucks provide a good clamping medium. Table 7 outlines COEFFICIENT OF THERMAL EXPANSION
cutting speeds and feeds with a typical cutting tool illustrated Depending on the weathering conditions, thermal expansion
in Figure 23. Forced-air cooling enables higher cutting rates. of LEXAN sheet can be larger than aluminium or steel.
However, care should be taken not to over-heat the material. Material m/m °C x 10-5
The use of cutting fluids to lubricate or cool the sheet is not
recommended. LEXAN sheet 6.7
Glass 0.7 - 0.9
Before starting trimming process, sheet should be secured
well to avoid vibration and to eliminate risk of cracking. Aluminium 2.1 - 2.3
Computerised trimming is a fully automatic milling process. It Steel 1.2 - 1.5
is extremely accurate and operates horizontally as well as
vertically. The use of a vacuum-operated jig avoids vibration of
the part, which helps create a smooth cut. Standard high
speed, two-sided cutting routers with tungsten carbide tips
are recommended, with a cutting speed of approximately
250 m/min at 25.000/30.000 RPM at a sheet thickness of
4 mm.

19
Fabricating

MACHINE SCREWS CAUTION

The majority of these screws are made from steel, but If the application calls for a screwed assembly, it is vitally
other metals and alloys are used for specialised important that the following recommendations are
applications. Several examples of this type of fastening considered.
system are shown on this page. Figures 24 and 25 • Do not use countersunk head screws as the ‘wedging’
illustrate sheet fastening devices known as ‘blind screw’ action of the countersunk head causes excessive hoop
and ‘blind nut’ anchors. stress on the sheet. This can lead to part failure.
• Be sure that all oil, grease and other coatings are
SELF-TAPPING SCREWS removed from the screws before assembly. Certain oils
Self-tapping screws are widely used within the plastics and greases can cause environmental stress cracking.
industry. Basically they produce their own thread as they
are driven into a hole and may be considered whenever
an assembly is likely to be dismantled and re-assembled.
While the majority of these screws are designed for
plastic moldings, with the aid of spring clips and washers
they can be adapted for sheet applications.

Figure 26 shows some typical fastening systems.

FIGURE 24 FIGURE 26
BLIND NUT AND BLIND SCREW ANCHOR TYPICAL SELF-TAPPING SCREW FASTENING SYSTEM
The stems washer is free-spinning
The stems washer is free-spinning
Available in a variety and
andpreassembled
preassembledto the
to screw.
the screw.
Availableof
in head
a variety of head styles. A controlled spring load is applied
styles A controlled spring load is applied
to the plastic.
to the plastic.
Sheet product Metal
Metalsheet, diecastoror
sheet, diecast
Sheet product
plastic
plasticof
of any
any thickness
thickness.

Threads insidewasher
Threads inside washer The standoff
standoff of
The ofthe
thestems
stems
provide resistancetoto
provide resistance washer carries
washer carriesclamp
clampload.
load
stripping inthin
stripping in thinsheet
sheetmetal.
metal Available
Available in a with a variety
variety
Available
Availableinina awide
wide of point styles.
of point styles
variety of thread forms.
variety of thread forms.

FIGURE 25
OTHER TYPICAL FASTENING SYSTEMS
Metal washer
Metal washerwith
with
laminated rubber
laminated rubber

Oversized hole
Oversized hole

Metal washer Sealing cap

Metal washer
with Sealing cap
with
laminated
laminated
rubber
rubber

LEXAN™ Sheet
Lexan sheet
Profiled
Profiledmetal
metal

20
Fabricating

RIVETING SYSTEMS For plastic-to-metal joints, the head of the rivet with a
Whilst riveting is a popular and effective assembly rubber washer should be against the plastic, and the hole
technique, certain guide-lines should always be followed in the sheet should be large enough to allow for thermal
when considering this type of assembly method. movement. Holesize is 1.5 x expanded rivet diameter.
Riveting can induce both radial and compressive stresses Rivet diameters should be as large as possible and
in the plastic sheet and precautions should be taken to spacing should be between 5-10 times their diameter.
distribute these forces over as wide an area as possible. SABIC recommends the use of aluminium, brass and
In a plastic-to-plastic assembly a metal back-up washer copper rivets. There are several different types of riveting
with laminated rubber is recommended to reduce the systems, however, the most popular is the ‘pop-rivet’.
compressive stresses. If the diameter of the rivet with a This type of rivet provides the means to assemble two
rubber washer is slightly bigger than the hole diameter, components together with access restricted to one side
then the hoop stresses will be transmitted to the washer only. Figures 27 and 28 illustrate typical rivet assemblies.
rather than the plastic sheet.

FIGURE 27
RIVET ASSEMBLY

Compatible
rubber washer

LEXAN™
Sheet

Metal back-up
washer
FIGURE 28
TYPICAL POP-RIVET ASSEMBLY Plastic
Plastic

Oversized hole Metal

Metal
Compatible Oversized hole
Compatible
rubber washer
rubber washer
Plastic
Plastic

Back-up
Back-up washer with
washer
with laminatedrubber
laminated rubber

21
Fabricating

MISCELLANEOUS FABRICATION TECHNIQUES Laser cutting of LEXAN sheet above 1mm products is not
Many different techniques are used to cut and fabricate recommended due to the following disadvantages:
polycarbonate LEXAN™ sheet products. • Rough cutting edges
• Carbon deposition on cutting edges
These techniques include: • Stress level increase in thick sheets
• Shearing • Discoloration
• Punching
• Tapping For further technical assistance and recommendations,
please contact SABIC’s Functional Forms business
While these techniques are used, they are not that you can find our contact details on the back page of
recommended since they either induce unnecessary this brochure. When working with LEXAN sheet, always
stress on the finished part or result in a poor surface consider safe and careful handling. The method and the
finish. With both shearing and punching the process purpose that you choose to utilize our products are
involves a shearing action with a guillotine or a punch beyond our control. Therefore, it is imperative that you
which tends to leave a roughly cut surface. This surface test our products to determine to your own satisfaction
often contains micro-cracks which may lead to whether our products, technical assistance and
premature failure. Tapping is possible in LEXAN sheet. information are suitable for your intended use and
However, the process is usually restricted to molded application. This application-specific test must at least
parts. Self-tapping screws or machine screws require a include analysis to determine suitability from a technical
minimum depth to achieve the necessary holding power as well as health, safety, and environmental standpoint.
and sheet products do not have the necessary thickness. Such testing has not necessarily been done by SABIC.
Unless we otherwise agree in writing, all products are
sold strictly pursuant to the terms of our standard
conditions of sale, which are available upon request.

FIGURE 29
WATER JET CUTTING EXAMPLE

22
Finishing, Decorating and Cleaning

FINISHING, DECORATING AND CLEANING For further technical assistance and recommendations,
The following section discusses the techniques and please contact SABIC’s Functional Forms business
processes that can be used to finishing, decorating and that you can find the contact details on the back page of
cleaning of LEXAN™ sheet and provides this brochure.
recommendations and advice on how you can create
the best finished products. When working with LEXAN sheet, always consider safe
and careful handling. The method and the purpose that
CHEMICAL RESISTANCE you choose to utilize our products are beyond our
The chemical resistance of a thermoplastic is dependent control. Therefore, it is imperative that you test our
upon five major factors: products to determine to your own satisfaction whether
our products, technical assistance and information are
1. Stress level in the application suitable for your intended use and application. This
2. Temperature application-specific test must at least include analysis to
3. Exposure time determine suitability from a technical as well as health,
4. Chemical concentration safety, and environmental standpoint. Such testing has
5. Type of chemical involved not necessarily been done by SABIC. Unless we otherwise
agree in writing, all products are sold strictly pursuant to
LEXAN resin has a good chemical resistance, at room the terms of our standard conditions of sale, which are
temperature, to a variety of dilute organic and inorganic available upon request.
acids. Water, vegetable oils, solutions of neutral salts,
aliphatic hydrocarbons and alcohols are also included in TABLE 8
this category. When a thermoplastic is attacked by a LEXAN SHEET CHEMICAL COMPATIBILITY SUMMARY
chemical it usually takes one of three forms. In the first
case the chemical is absorbed into the plastic, and Chemical class Effects
plasticisation and/or crystallisation occurs. Acids (Mineral)  o effect under most conditions of
N
concentration and temperature.
The visible signs of this type of attack are swelling or Alcohols Generally compatible.
surface whitening. LEXAN resin is affected in this way by Alkalis  cceptable at low concentration
A
partial solvents such as low molecular weight aldehydes andtemperature. Higher concentrations and
and ethers, ketones, esters, aromatic hydrocarbons and temperatures result in etching and attack as
perchlorinated hydrocarbons. In addition, chemical evidenced by decomposition.
attack ranging from partial to complete destruction of Aliphatic Generally compatible.
LEXAN resin occurs in contact with alkalines, alkali salts, Hydrocarbons
amines and high ozone concentrations. The third type of Amines Surface crystallisation and chemical attack.
attack is often the most difficult to predict since Aromatic Solvents and severe stress-cracking agents.
environmental conditions dictate whether or not the Hydrocarbons
plastic will be affected. Combinations of certain Detergents and  ild soap solutions are compatible.
M
environments, coupled with stress and/or strain upon Cleaners Strongly alkaline ammonia materials should
the material, cause stress cracking or crazing of the be avoided.
polycarbonate. Crazing can be induced at moderate to Esters Cause severe crystallisation. Partial solvents.
high stress levels by low molecular weight hydrocarbons.
Fruit Juices and Soft  ompatible at low stress levels.
C
Drinks Some concentrates not recommended.
Products such as acetone and xylene may cause stress
Gasoline  ot compatible at elevated temperatures
N
cracking even at very low stress levels and should and stress levels.
therefore be avoided. Taking into account the
Greases and Oils P ure petroleum types generally compatible.
complexity of chemical compatibility, all chemicals Many additives used with them are not, thus
which come into contact with polycarbonate should be materials containing additives should be
tested. For sheet products the most common contact is tested.
with sealants, gaskets and the various cleaning media. Halogenated Solvents and severe stress-cracking agents.
Chemical compatibility testing, table 9, is an on-going Hydrocarbons
process at SABIC's Functional Forms business and Ketones  ause severe crystallisation and stress-
C
many standard products have already been tested. cracking. Solvents.
Silicone Oils and Generally compatible up to 80 °C.
A complete list of compatible cleaners, gaskets and Greases
sealants is available upon request. However, a shortened
list of some of the more common compounds is outlined
in the respective sections in Table 8.

23
Finishing, Decorating and Cleaning

TABLE 9 CLEANING PROCEDURE FOR LARGE AREAS -

LEXAN MARGARD SHEET CHEMICAL RESISTANCE AUTOMATED
1. Clean the surface using a high-pressure water cleaner
Chemicals Effects
(max. 100bar or 1,450psi) and/or a steam cleaner. We
Uncoated PC LEXAN MARGARD suggest that a test be made on a small area, prior to
Sheet MR5E Sheet cleaning the entire sheet.
Toluene W/S OK 2. Use of additives to the water and/or steam should be
Acetone S OK avoided.
Methylethylketone S OK OTHER IMPORTANT INSTRUCTIONS FOR CLEANING
Dichloromethane W/S OK LEXAN SHEET:
Sulphuric acid OK OK • Never use abrasive or highly alkaline cleaner on LEXAN
(95-97%) polycarbonate materials.
Hydrochloric acid OK OK • Never use aromatic or halogenated solvents like
(32%) toluene, benzene, gasoline, acetone or carbon
Ammonia (25%) OK OK tetrachloride on LEXAN polycarbonate materials.
Thinner (Sikkens W/S OK • Use of incompatible cleaning materials with LEXAN
1-2-3) sheet can cause structural and/or surface damage.
Super Gasoline W/S OK • Contact with harsh solvents such as methyl ethyl
Diesel Fuel OK OK
ketone (MEK) or hydrochloric acid can result in surface
degradation and possible crazing of LEXAN sheet.
Fuel C OK OK
• Never scrub with brushes, steel wool or other abrasive
Hairspray OK OK materials.
• Never use squeegees, razorblades or other sharp
W = surface whitening instruments to remove deposits or spots.
S = surface dissolution
• Do not clean LEXAN polycarbonate sheet in direct
sunlight or at high temperatures as this can lead to
LEXAN SHEET CLEANING RECOMMENDATIONS staining.
These cleaning recommendations apply to all LEXAN • For all mentioned chemicals consult the
polycarbonate sheet products, including, but not limited manufacturer’s Material Safety Data sheet (MSDS) for
to, LEXAN solid sheet and signs, LEXAN coated proper safety precautions.
MARGARD™ sheet and LEXAN multiwall sheet. Periodic
cleaning using correct procedures can help to prolong
ADDITIONAL IMPORTANT CONSIDERATIONS FOR
service life. For cleaning, it is recommended that the
MULTIWALL, CORRUGATED AND SIGN SHEET:
following instructions be adhered to:
• Cleaners and solvents generally recommended for use
CLEANING PROCEDURE FOR SMALL AREAS – on polycarbonate are not necessarily compatible with
MANUAL the UV-protected surfaces of LEXAN multiwall sheet,
1. Gently wash sheet with a solution of mild soap and corrugated and sign polycarbonate materials.
lukewarm water, using a soft, grid-free cloth or • Do not use alcohols on the UV-protected surfaces of
sponge to loosen any dirt or grime. LEXAN sheet.
2. Fresh paint splashes, grease and smeared glazing • Never clean the Dripgard surface of LEXAN multiwall
compounds can be removed easily before drying by sheet and corrugated sheets.
rubbing lightly with a soft cloth using petroleum ether
(BP65), hexane or heptane. Afterwards, wash the
sheet using mild soap and lukewarm water. GRAFFITI REMOVAL FROM LEXAN MARGARD SHEET
3. Scratches and minor abrasions can be minimized by • Butyl cellosolve can be used to remove paints,
using a mild automobile polish. We suggest that a test marking pen inks and lipstick stains. Afterwards, wash
be made on a small area of LEXAN sheet with the the sheet using mild soap and lukewarm water.
polish selected and that the polish manufacturer’s • Masking tape, adhesive tape or lint removal tools can
instructions be followed, prior to using the polish on be used to lift off old, weathered paints.
the entire sheet. • To remove label stickers, the use of kerosene or
4. Finally, thoroughly rinse with clean water to remove petroleum ether (BP65°) can be generally effective. If
any cleaner residue and dry the surface with a soft solvent doesn't penetrate to sticker material, apply
cloth to prevent water spotting. heat (hair dryer) to soften the adhesive and promote
removal of the sticker. Afterwards please follow the
cleaning procedure for small areas as outlined above.

24
Finishing, Decorating and Cleaning

PAINTING SCREEN PRINTING

Be it simple or complex, decorative or functional, Silk-screen printing is a well-established process that
hand-controlled or automatic, painting LEXAN™ sheet offers a wide variety of options for a decorative finish.
products offers the designer the freedom to create a However, in most cases the printing must be
dramatic effect in a sign or a simple colour code for accomplished prior to installation, since the process is
instructions. Provided certain basic recommendations basically a horizontal one and is generally restricted to
are followed, most techniques used to apply paint to small-to-medium part sizes. The process involves forcing
wood, metal, building materials and other plastics can viscous inks through a very fine, thin screen that is
be used for LEXAN sheet products. The important factor treated in such a way as to allow the ink only through to
is once again one of compatibility. Only compatible paint the patterned area. Special inks are required that are
systems should be used. Some paint and thinner systems formulated so that they will pass through the mesh,
are not compatible with LEXAN sheet products and can while being sufficiently viscous to prevent run-out. This
cause stress cracking and a reduction in impact type of finishing operation is often used in the sign
performance. Paint systems for LEXAN sheet should be industry and a wide variety of screen printing inks and
flexible. Combinations of flexible primers and hard top thinners are available. Once again the importance of
coats could also work. Any paint system should be chemical compatibility cannot be over-emphasised and
flexible at subzero temperatures. In view of adhesion only paints and thinners recommended for use with
problems, painting is not recommended for decorating LEXAN sheet products should be used. This process is not
the coated sides of either LEXAN™ MARGARD™ MR5E suitable for decorating LEXAN MARGARD MR5E, LEXAN
sheet or LEXAN MARGARD FMR sheet. MARGARD FMR5XT sheets. The one side coated grades
of LEXAN MARGARD sheet such as LEXAN MARGARD
PAINTING RECOMMENDATIONS HLG5, LEXAN MARGARD FLG5XT and LEXAN MARGARD
• Clean the sheet and remove static with a damp HLGA2 sheets can be screenprinted at the uncoated
chamois cloth or ionised air treatment. side.
• Avoid too high a delivery rate and too heavy a wet
coat thickness. SCREENING RECOMMENDATIONS
• Allow adequate drying before applying spray mask to • Use only compatible paints and thinners.
painted areas. • Do not mix different paints and inks.
• Do not expose painted faces to a low temperature and • Do not substitute spray thinners for screen thinners.
high humidity environment during drying. • Do not add solvents such as toluene, xylene, cellulose
• Use dry air in all compressed air lines. Drain water taps acetate, methylethylketones or other related
frequently. chemicals to the inks.
• Paint solvents should be evaporated from the paint • Use water-moistened chamois or soft cloths to avoid
surface as quickly as possible by providing appropriate abrasion or scratching during cleaning prior to
air circulation. printing.
• Follow recommended machining and trimming • Use the correct colour of paint to achieve opacity
practices for finishing post-decorated faces. required.
• Provide good air circulation and ventilation during
For painting systems please consult SABIC. drying.
• If a digital printing process is used, only print on the
sheet side which has the unprinted masking.

For screen printing inks please consult SABIC.

25
Finishing, Decorating and Cleaning

ANTI-STATIC TREATMENT However, it is a technology that often causes the most

As common with all insulating materials, LEXAN™ sheet problems. While some adhesives/sealants form a flexible
tends to build up a static charge. It is often necessary to bond, others form a rigid bond. Some are capable of
clean and discharge the surface prior to painting or filling gaps, while others are for close contact. Some can
screen printing. Wiping the sheet with a damp chamois withstand high temperatures, while others cannot. The
or applying de-ionised air to the surface is often all that is choice of adhesive types is vast, as are the applications
required. Another effective method in minimising static areas. It is vitally important, therefore, to select the
charge build-up is control of the relative humidity: the adhesive carefully, ensuring its compatibility with the
higher the relative humidity, the lower the static charge materials being used and the working environment. The
build-up will be. Typically, relative humidity above 60% is importance of chemical compatibility was discussed in
effective. Section 3.1, and adhesive selection and testing is an
ongoing process at SABIC Structured Products. A
ADHESIVES AND SEALANTS comprehensive data-base of compatible adhesives is
The use of adhesives to bond dissimilar materials is now available, and in all cases it is strongly recommended
universal. Over the past twenty years polymer that all adhesives are checked for compatibility before
technologists have developed adhesives with a wide use. Table 10 presents an overview of some of the initial
range of properties and application profiles. Adhesion criteria used to select an adhesive and Table 11 provides
technology has become a branch of the plastics industry a list of compatible adhesives indicating generic types,
in its own right, offering a technique that is one of the trade names and application areas. Figure 30 outlines
most efficient, effective and economical methods of some typical joint configurations
joining plastic components to themselves and to other
materials.

TABLE 10
ADHESIVE SELECTION CHART FOR LEXAN SHEET PRODUCTS (POLYCARBONATE)
Adhesive Type Joins LEXAN sheet to Supplier
Epoxy Metals, Plastics, rubbers 3M Company
Epoxy Plastics 3M Company
Polyurethane Plastics, Metals, wood Henkel
Polyurethane Plastics, Metals, wood Henkel
Hot Melt Plastics, Wood 3M Company
Hot Melt Plastics, Wood Glass, Ceramics Henkel
Silicone LEXAN uncoated sheet, LEXAN EXELL D sheet, LEXAN MARGARD MR5E
™ ™ ™
Momentive Performance
sheet and LEXAN MARGARD FMR sheet - Building Materials Materials
MS polymer LEXAN uncoated sheet, LEXAN EXELL D sheet, LEXAN MARGARD MR5E Bostik
sheet and LEXAN MARGARD FMR sheet - Building Materials
Tapes Plastics, Glass, Metals 3M Company
Tapes Metals / Plastic Fasson
Tapes — Velcro
Tapes — Multifoil
Tapes — Sellotape
The actual choice of adhesive will depend upon the design of the joint, the circumstances under which the joint will be used and the prevailing environmental
conditions. In all cases the adhesive type should be fully tested under exact conditions to determine complete compatibility and performance.

TABLE 11
ADHESIVE GROUPS AND PROPERTY PROFILE
Impact Resistance Moisture Behaviour Number of Components Temperature Limits (°C) Gap Filling
Epoxy Bad Very Good 1 or 2 200 + +
Polyurethane Very Good Good 1 or 2 140 +
Hot Melt Good Good 1 60 +/-
Silicone Excellent Very good 1 or 2 250 +

26
Finishing, Decorating and Cleaning
1.
1. Double
Double Butt
Butt Lap
Lap Joint
FIGURE 30 Joint

JOINT DESIGN CONFIGURATIONS

LAP JOINTS

The joggle lap joint allows a more uniform 2. 1. Joggle

2. Joggle
Joggle Lap Joint Lap
Lap Joint Joint
stress distribution than a single tapered lap
joint.

A tapered single lap joint is more efficient than 3. 2. Tapered Single Lap Joint
3. Tapered
Tapered Single
Single Lap
Lap Joint
Joint
a single lap joint, allowing for bending of the
joint edge under stress.

4.
4. 3. Double
Double
4. Double
Double
Lap
Lap Joint
Lap Joint
Joint Lap Joint
A double lap joint allows for greater rigidity
than a single lap joint.

A simple lap joint could create cleavage and 5. 4. Simple

5. Simple
Simple Lap Joint Lap
Lap Joint Joint
peel stress under loading, particularly in
bonding thin sheets.

A round lap joint can be used to add rigidity 6.

6. Round
Round Lap
Lap Joint
5. RoundJoint Lap Joint
and strength to an assembly and minimise the
deflection of flat sheets.

7.
7. Double
Double Scarf
Scarf Lap
Lap Joint
Joint

27
CONTACT US
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