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PC (Polycarbonate)

polymer

amorphous engineering thermoplastic polycarbonate

PolycarbonateBPA-PCMakrolon (Covestro)Lexan (SABIC)Stratasys PCPC-ISO
Density
1.20 g/cm³
UTS (FDM as-built (XY))
58–75 MPa
Elongation (FDM as-built (XY))
3.0–9.0 %
Elastic modulus
2–3 GPa
Glass transition (Tg)
143–150 °C

Mechanical & thermal properties — 2 conditions

PropertyFDM as-built (XY)FDM as-built (Z — upright)
Elastic modulus2–3 GPa—
Ultimate tensile strength58–75 MPa35–52 MPa
Elongation at break3.0–9.0 %1.0–6.0 %
Density1.18–1.22 g/cm³—
Glass transition (Tg)143–150 °C—
As-built surface Ra9.0–22.0 µm—

Values shown as min–max where a spread is reported, otherwise as typical ± unit. Ranges reflect inter-source variation, not single-sample scatter. All values are for AM-processed specimens unless noted.

Engineering considerations

  • Drying protocol is non-negotiable: PC must be dried at 120°C for 4–6 hours in a desiccant oven before printing. Print from a sealed dry-box with desiccant during the build. Any visible steam, sizzling, or surface bubbling indicates wet filament — stop and re-dry. The single most common cause of PC FDM part failure is moisture-contaminated filament.
  • Chamber temperature 70–90°C: lower chamber temperatures allow PC to cool too quickly between layers, creating thermal stress and delamination. 90°C chamber is the recommended target for structural parts. If using an open-frame printer with an enclosure, actively heat the enclosure and verify with a thermometer — convective equilibrium is slow.
  • Nozzle temperature 260–280°C: PC requires higher melt temperature than ABS (230–250°C). Sub-optimal nozzle temperatures produce brittle, under-bonded parts with very low Z-direction elongation. Use 270°C as a starting point and increase if layer adhesion is poor.
  • PC vs ABS selection: for applications not requiring PC's specific advantages (highest impact strength, HDT >120°C, optical clarity, autoclave sterilisability), ABS is significantly easier to print and less moisture-sensitive. Select PC only when at least one of these properties is a hard requirement.
  • PC-ABS blend alternative: PC/ABS blends (e.g., Stratasys PC-ABS) combine ABS's processability with PC's strength improvements. PC-ABS prints at lower temperature (~245°C), requires less aggressive chamber heating, and is substantially easier to work with than pure PC. Consider PC-ABS when moderate PC properties suffice.
  • Post-processing: PC cannot be acetone vapour smoothed. Achieve smooth surfaces by wet sanding (220 → 400 → 800 grit with water), followed by polishing compound for optical applications. Flame polishing works on PC for localised edge clarification. Painting requires PC-compatible primer — test adhesion before production use.
  • Impact testing interpretation: PC's high bulk impact strength does not fully translate to FDM parts. The layer interface is the failure path. For impact-critical applications, orient part so impact loading is in-plane (XY) with layer interfaces, not peeling them apart. Run Charpy impact tests on FDM coupons in both XY and Z orientations before qualifying.

Advantages

  • Highest impact strength of common FDM polymers — PC is the material of choice when part cannot break in service
  • Highest heat resistance of common FDM polymers: Tg 147°C, HDT 138°C at 1.8 MPa — suitable for 120°C continuous service
  • Optical clarity in natural (transparent) colour — PC FDM parts can transmit and diffuse light; unique among opaque FDM defaults
  • Good chemical resistance to dilute acids, aliphatic hydrocarbons, and alcohols — suitable for laboratory and industrial environments
  • PC-ISO grade is sterilisable by steam autoclave (134°C / 3 bar, short cycles) — enables sterile medical device prototypes and surgical guides
  • Higher tensile strength than ABS (68 vs 42 MPa XY) — stronger structural parts from same geometry
  • Good dimensional stability: lower CTE than ABS, less post-build distortion on controlled-temperature cooling

Limitations

  • Extremely hygroscopic: PC absorbs 0.35% moisture at 50% RH within hours. Wet PC produces severe voids, surface bubbling, poor layer adhesion, and Z-direction delamination. Must be dried at 120°C for minimum 4–6 hours before printing. Use sealed dry-box during printing for long builds
  • Heated chamber mandatory: PC requires 70–90°C chamber temperature. Without it, warping and delamination are severe even on small parts. Desktop printers without a heated enclosure are not suitable
  • High nozzle temperature required (260–280°C): standard PTFE-lined hotends are limited to 240°C. All-metal hotend with hardened nozzle required for open-format FDM systems. Stratasys Fortus machines are pre-qualified
  • UV yellowing: PC without UV stabiliser yellows under prolonged UV exposure. Natural/transparent PC parts become yellow-tinted outdoors. UV-stabilised grades or UV-protective coatings required for outdoor applications
  • Attacked by aromatic solvents and ketones: PC dissolves in DCM (dichloromethane), chlorinated solvents, acetone, and MEK. Cannot be acetone vapour smoothed (unlike ABS). Avoid contact with common cleaning solvents and adhesives
  • Higher cost than ABS: PC filament costs 2–4× more per kilogram than commodity ABS. PC-ISO grade (sterilisable) is significantly more expensive
  • Not recyclable in standard streams: BPA-PC is not accepted in most municipal recycling — industrial recycling only. Environmental consideration for high-volume use

Typical applications

Functional engineering prototypes requiring highest impact strength among common FDM polymersSterilisable medical device housings and surgical guides (PC-ISO grade, 134°C steam autoclave compatible)Optical components and light pipes — PC natural colour is transparent, achieves light transmissionElectronic device enclosures requiring UL94 compliance (PC grades with flame retardant additives)Automotive interior and under-hood components requiring HDT above 130°CJigs and fixtures for elevated-temperature manufacturing processesTooling masters for low-volume casting requiring dimensional stability at elevated temperatureProtective covers and shields requiring combination of clarity and impact resistanceIndustrial machine guards and safety enclosures where impact and heat resistance are critical

Industries

automotiveconsumerindustrialmedicalelectronics

Standards & certifications

iso-527-3-2018established

Tensile testing of plastics — applicable to FDM PC specimens

consumerindustrialautomotivemedical

ISO 527-2 Type 1B specimens standard for FDM PC mechanical testing. Print temperature and drying protocol must be documented alongside test data — PC properties vary widely with these parameters.

Compatible AM processes (1)

Fused Deposition Modelling50–300 µm layers

Other polymer materials

PA12 (Polyamide 12)semi-crystalline thermoplastic polyamidePA12-CF (Carbon Fibre PA12)carbon fibre reinforced polyamide-12 compositePA11 (Polyamide 11)semi-crystalline thermoplastic polyamide (bio-based)PEEK (Polyether Ether Ketone)semi-crystalline high-performance aromatic thermoplasticPEKK (Polyetherketoneketone)semi-crystalline high-performance aromatic thermoplastic (PAEK family)ULTEM 1010 (Polyetherimide PEI)amorphous high-performance thermoplastic (polyetherimide family)PLA (Polylactic Acid)semi-crystalline bio-derived thermoplastic polyesterPETG (Polyethylene Terephthalate Glycol)amorphous/semi-crystalline copolyester thermoplasticABS (Acrylonitrile Butadiene Styrene)amorphous engineering thermoplastic terpolymerTPU (Thermoplastic Polyurethane)elastomeric thermoplastic block copolymerASA (Acrylonitrile Styrene Acrylate)amorphous engineering thermoplastic terpolymerNylon PA6 / PA66 (Polyamide 66)semi-crystalline engineering thermoplastic polyamidePP (Polypropylene SLS/MJF)semi-crystalline thermoplastic polyolefinPEBA (Polyether Block Amide / TPA)thermoplastic elastomeric polyether block amide copolymer

Related calculators

Extrusion WidthActual extrusion width from nozzle diameter, layer height, and flow rate multiplier. Wall perimeter count from nominal thickness. FFF/FDM design rule compliance check.RoughnessTheoretical Ra and Rz from layer thickness and surface angle (staircase effect). Upward, downward, and vertical faces. LPBF, SLS, FDM, SLA, DED. Per Grimm et al.Dimensional AccuracyExpected dimensional deviation (mean bias ± 1σ) for XY and Z axes by process, material class, and geometry type. Based on aggregated published accuracy datasets. Answers: what tolerance can I realistically hold?Cost-Per-Part EstimatorMachine hourly + material + labor + post-processing → unit cost with margin. Currency-agnostic.
Last reviewed: 2026-05-13 · v1 · Sources: covestro-pc-lm2527-2022, farbman-2019-pc-fdm, cantrell-2017-fdm-mech-pc, iso-527-3-2018

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