The short answer
The safest fix is the same PC grade from a second source. If PC itself has to change: PC/ABS or ABS for opaque housings at moderate temperature, acrylic for clear parts that do not need high impact, copolyester for clear parts that need chemical resistance, and PEI or PSU for more heat.
Polycarbonate is tough, clear and heat resistant, which is why it is everywhere. When a PC grade goes short, gets expensive, or keeps cracking in a chemical environment, buyers look at alternatives. The right one depends on which of PC's properties the part actually uses.
Polycarbonate alternatives compared
| Alternative | Works best for | Watch for |
|---|---|---|
| PC from another source | Any PC part | Match grade, flow, flame rating and color; lowest-risk route |
| PC/ABS | Housings, enclosures, interior trim | Opaque; lower heat than PC; easier to mold |
| ABS | Housings and consumer parts at moderate temperature | Lower impact and heat than PC; opaque |
| Acrylic (PMMA) | Clear lenses, displays, light covers | Much more brittle; better clarity, scratch and UV resistance |
| Copolyester (PETG-type) | Clear parts needing chemical resistance | Lower heat than PC; good toughness |
| PEI or PSU | Clear amber or opaque parts needing more heat | Higher cost; different processing |
General guidance. Check impact, heat, flame rating and approvals for the specific grade.
What to check before switching
- Does the part need clarity? That narrows it to acrylic, copolyester, clear PC from another source, or PSU/PEI if an amber tint is acceptable.
- How much impact does it see, and at what temperature?
- What heat does it see in service?
- Which chemicals touch it? PC is sensitive to many cleaners and solvents.
- Flame rating and approvals: UL ratings belong to the exact grade.
See PC vs. acrylic, ABS vs. PC vs. nylon and environmental stress cracking.
How we help
Send the PC grade you run now and what the part needs. A polymer chemist will look for a second PC source and suggest an alternative where it fits, with a COA on every lot, tested to ASTM or ISO methods. We aim to send your quote within one to three business days.
Common questions
What can replace polycarbonate?
It depends on what the part needs from PC. For clarity and scratch resistance without high impact, acrylic. For toughness at lower cost and heat, ABS or PC/ABS. For clear parts with chemical resistance, copolyester (PETG-type grades). For more heat, PEI or PSU.
Is PC/ABS a good substitute for polycarbonate?
For many housings and enclosures, yes. It is easier to process, more forgiving in thick sections and often cheaper, but it is opaque and has lower heat resistance than PC.
Can acrylic replace polycarbonate?
For clear parts that do not need high impact strength, often yes. Acrylic is clearer, more scratch resistant and weathers better, but it is far more brittle than PC.
Why do polycarbonate parts crack?
Usually environmental stress cracking from chemicals such as cleaners, oils or solvents acting on molded-in stress, or from molding wet resin. Changing resin may help, but check processing and drying first.
Does switching from PC need requalification?
Usually. Impact, heat, flame rating, clarity and chemical resistance all change. Trial first and requalify approved parts.
Tell us the PC grade you run now
A polymer chemist reviews every request, then matches your grade or finds a qualified equivalent and prices it.
What to send for an accurate quote
- The grade name, from any supplier, or a data sheet
- Color (natural, black or a custom match)
- Fill type and percentage, if any
- Melt flow, if you know it
- Quantity for this order and what you use in a year
- Ship-to city and state or province