Injection Molding: Flat Polycarbonate Lexan Explained

Injection molding is a versatile manufacturing process used to create a wide array of products from various materials, including flat polycarbonate Lexan. This article will delve into the details of this process, focusing specifically on the use of flat polycarbonate Lexan. We will explore the properties of this material, the steps involved in the injection molding process, and the applications of the finished product.

Polycarbonate Lexan is a type of thermoplastic polymer known for its exceptional strength, transparency, and resistance to impact and heat. It is widely used in industries such as automotive, electronics, and construction due to these properties. Flat polycarbonate Lexan, in particular, is favored for its versatility and ease of use in the injection molding process.

Properties of Flat Polycarbonate Lexan

Flat polycarbonate Lexan is a high-performance material that offers a unique combination of properties. It is incredibly strong and durable, able to withstand high levels of impact without breaking or deforming. This makes it an ideal material for use in applications where durability and safety are paramount.

Another key property of flat polycarbonate Lexan is its excellent transparency. It allows up to 90% of light to pass through, making it comparable to glass in this regard. However, unlike glass, it is much more resistant to breakage and can be molded into complex shapes, making it a more versatile material.

Thermal Properties

Flat polycarbonate Lexan has excellent thermal properties, making it suitable for use in a wide range of temperatures. It can withstand temperatures as high as 130 degrees Celsius without losing its shape or properties. This makes it an ideal material for use in applications where exposure to high temperatures is a possibility.

Furthermore, it has a low coefficient of thermal expansion, meaning it does not expand or contract significantly with changes in temperature. This stability is crucial in applications where dimensional accuracy is important.

Electrical Properties

Flat polycarbonate Lexan also has good electrical properties. It is an excellent insulator, making it suitable for use in electrical and electronic applications. It also has a high dielectric strength, meaning it can withstand high voltages without breaking down.

Additionally, it has a low dissipation factor, which means it loses very little energy in the form of heat when an electric current is passed through it. This makes it an efficient material for use in electrical applications.

Injection Molding Process

The injection molding process involves melting the flat polycarbonate Lexan and injecting it into a mold under high pressure. The material is then cooled and solidified in the mold before being ejected as a finished part. This process allows for the production of complex parts with high precision and repeatability.

One of the key advantages of the injection molding process is its ability to produce large volumes of parts quickly and efficiently. This makes it a cost-effective method for mass production. Additionally, the process is highly automated, reducing the need for manual labor and increasing the consistency of the finished parts.

Preparation of Material

Before the injection molding process can begin, the flat polycarbonate Lexan must be prepared. This involves drying the material to remove any moisture, as moisture can cause defects in the finished parts. The material is typically dried in a desiccant dryer at a temperature of 120 degrees Celsius for 4 hours.

Once the material is dry, it is fed into the injection molding machine. The machine heats the material to its melting point, turning it into a liquid state. This molten material is then ready to be injected into the mold.

Injection and Cooling

The molten flat polycarbonate Lexan is injected into the mold under high pressure. This ensures that the material fills the entire mold cavity, capturing all the details of the mold. The pressure is maintained until the material has cooled and solidified.

Once the material has solidified, the mold is opened and the finished part is ejected. The part may require additional finishing processes, such as trimming or polishing, to achieve the desired final appearance.

Applications of Injection Molded Flat Polycarbonate Lexan

Injection molded flat polycarbonate Lexan is used in a wide range of applications due to its unique properties. Its strength, durability, and transparency make it an ideal material for use in industries such as automotive, electronics, and construction.

In the automotive industry, it is used to make parts such as headlight lenses, instrument panels, and sunroofs. Its high impact resistance and transparency make it a safer alternative to glass in these applications.

Electronics Industry

In the electronics industry, flat polycarbonate Lexan is used to make parts such as phone cases, computer housings, and TV screens. Its excellent electrical properties make it an ideal material for these applications.

Furthermore, its ability to be molded into complex shapes allows for the production of intricate parts with high precision. This is crucial in the electronics industry, where parts often have complex geometries and tight tolerances.

Construction Industry

In the construction industry, flat polycarbonate Lexan is used to make parts such as windows, skylights, and roofing panels. Its strength and durability make it an ideal material for these applications, as it can withstand harsh weather conditions and heavy loads.

Additionally, its transparency allows for the passage of natural light, reducing the need for artificial lighting and contributing to energy efficiency.


Injection molding of flat polycarbonate Lexan is a complex process that requires a deep understanding of the material and the molding process. However, the benefits of this process are clear. It allows for the production of high-quality parts with complex geometries and tight tolerances, making it an invaluable tool in many industries.

With its unique combination of strength, durability, transparency, and thermal and electrical properties, flat polycarbonate Lexan is a versatile material that can meet the demands of a wide range of applications. Whether it’s in the automotive, electronics, or construction industry, this material has proven its worth time and time again.

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