Lexan® Thermoplastic Machining

Lexan is a brand name and not the name of the material itself, polycarbonate resin thermoplastic is what it's more commonly referred to as. In a nutshell, Lexan is that it’s a solid substance that can deform in extreme heat is exhibit excellent toughness, high impact strength, and a high modulus of elasticity. Most types of Lexan thermoplastic offer transparency and high optical clarity. This material is relatively easy to work with, and Upland Fab are experts in machining complex, high precision parts from Lexan polymers.

Benefits of Working with Lexan Polymers

Lexan thermoplastic provides high heat deflection, very low moisture absorption, favorable low frequency and high voltage insulating characteristics, making it an ideal material for electrical and electronic components. Lexan also provide high tensile, shear, and flexural strength, and boasts an impact strength of 250 times greater than that of glass and 30 times greater than that of acrylic. Excellent creep resistance and flow resistance, a low coefficient of thermal expansion, and low deformation characteristics under load further improve the materials’ performance in high temp applications.

Lexan polymers are highly versatile materials that are useful for a broad range of applications. Common uses for Lexan include equipment housings, electrical connectors, insulators, and fittings, relay components, medical devices, and many more.

Sheet grade Lexan is also called Lexan (GE) or Makrolon (Bayer) whereas acrylic sheet Lexan is commonly referred to as Lucite.  Both Lexan and Lucite have benefits and drawbacks. Both are two of the most frequently used see-through plastics but Acrylic will have a shinier surface but is easier to crack. Where Lexan / polycarbonate is stronger and more impact resistant it's also easier to scratch.

There are many grades of Lexan polycarbonate thermoplastic available, from general purpose to machine grade to glass-filled and more. Each grade offers unique characteristics that may make it better suited to your application than others. Contact us to discuss your material requirements.

High Precision Machining of Lexan Thermoplastic Parts

When working with Lexan, Upland Fab utilizes multi-axis machining to ensure that tight tolerances are maintained from the first part to the last. Our CNC machining capabilities enable us to produce consistently high precision parts, with minimal handling and fixturing requirements. In many cases, even the most complex parts can be completed in a single operation for fast turnarounds.

Thanks to our DPD/MBD processes (Digital Product Definition/Model-Based Definition), we can work directly from your completed CAD models. Working straight from your digital design files eliminates manufacturing errors and ensures that your parts match your exact requirements. We can deliver cost-effective Lexan thermoplastic parts that are 100% on spec.

Lexan Machining for Any Industry

Lexan polymers offer many advantages to machining productions across industries. Common uses for Lexan thermoplastic include:

• Medical: Lexan is used throughout the healthcare industry due to its chemical resistance and ability to be sterilized. It is popular for manufacturing protective shields and barriers, device housings, labware, and other hospital furnishing and fixtures.
• Defense: Military components must meet strict regulatory guidelines, and Lexan thermoplastics are up to the task. Lightweight and high-strength, Lexan is used to manufacture vehicle components, jet fighters, and more.
• Semiconductor & Electronics: Offering high dielectric strength and insulation properties, Lexan is a commonly chosen material for manufacturing enclosures, electrical components and switches, printed circuit boards, and other parts.
• Aerospace: Lexan’s excellent strength-to-weight ratio makes it an ideal option for aerospace assemblies where weight reduction is essential. It is often used to produce windows, cockpit instrumentation, lighting systems, aircraft engine parts, and more.

Top-Flight Communication Keeps You Up to Date

With Upland Fab, you’ll have a single point of contact throughout every stage of your project. We know the importance of effective communication, and we’ll provide reliable, consistent updates to keep you informed from the first step to the last.

Other Materials We Work With

Are you looking for another material? We have the ability to machine many different materials take a look below at some of the other plastics we work with. 

Contact Upland Fab to Learn More About Machining Lexan Polymers

Upland Fab has been providing top-flight plastic and composite machining in Southern California since 1970. Contact Upland Fab to discuss Lexan thermoplastic machining for your project, or get a quote to get started.