CUTTING LARGE POLYCARBONATE SHEETS - BEST METHODS
Written By Mark Batson Baril


How would we best cut 1.2mm (.047") polycarbonate (50,000 sheets) using a conventional flatbed - platen style machine? The sheet size is 1,524 x 762 (60" x 30"). The part is a simple rectangular shape with rounded corners, but with 32 keyhole shaped cut outs. These keyholes are 9.52mm x 12.7mm (3/8" x 1/2"). What would be the best type of rule, etc... to use? We are used to cutting paper...

Polycarbonate, very commonly known in the US by its trade name Lexan, is a very diecuttable material. It is used constantly in the nameplate, membrane switch and sign industries due to its toughness, ability to be printed on, electrical non-conductivity, and general availability.

We would make just a few suggestions that may make your life a bit easier going from paper to Polycarbonate.

  • Feed the sheets and strip the waste the same way you would treat similar shaped paper products.
  • Use fewer nicks to start with than you normally would and try to get away with just the natural nicks caused by the rule joints. The material will tend to stay with itself even though it has been cut and it can be a real bear to separate if it has not cut all the way through or if too big a nick has been made to get it through the press.
  • Use 3 point sideface rule with a ground edge. Face the bevel to the waste. Test cut your keyholes with long bevel and sideface before you make them all, especially if their size is critical. A simple one up test die may save you a great deal of time.
  • Use 3/4" base material (assuming .937" high rule) to support the rule as high as you can. Under the strain of this thickness of this material, the rule will want to move with a thinner base material. Movement will make it more difficult to make-ready and maintain ready. Etch away the front of the board if need be to make way for any feed devices like gripper bars.

    Other than that, you shouldn’t have too many problems. It will make one heck of a POP when it cuts compared to paper, but that is normal.

    Depending on your quantities you may want to take a look at laser cutting, waterjet cutting and perhaps even routing the parts.

    Please contact Cut Smart if you would like more information on this subject.

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