Polycarbonate Laminating: The Ultimate Guide

Polycarbonate lamination is a popular plastic fabrication technique that plays a critical role in industries.

Through lamination, you will make polycarbonate sheet more functional, with superior properties.

But, how can you achieve this?

Today’s guide takes you through all the details of polycarbonate lamination – from benefits, classification, considerations, common problems, buying lamination machine, etc.

Now, let’s dive right in.

What is Polycarbonate Laminating?

This refers to the process or technique of manufacturing a polycarbonate sheet by bonding layers of the material together.

Polycarbonate panel

Polycarbonate panel

It is a crucial process which requires quite a lot of knowledge and often takes place in well-equipped laboratories.

The essence of undertaking this procedure is always to enable the sheet to attain the necessary stability, and strength.

In other instances, the purpose of this technique could also be to allow the material to attain sound insulation and ideal appearance among others.

Ordinarily, polycarbonate laminating often happens through heating or by using adhesives.

It all depends on the type of laminate you are using.

And that is why in many instances you’ll realize that polycarbonate laminating can be put together by either cohesion or adhesion.

If you’re keen enough, you’ll notice that polycarbonate laminates are often various layers materials that are held together by a plastic material.

Polycarbonate lamination

Polycarbonate lamination

What’s more is that the only way to distinguish a laminated polycarbonate is by understanding that they are made of layers of material.

So that’s primarily what polycarbonate laminating is all about.

However, before we continue, let’s first find out some of the reasons why this technique could be essential.

Why Laminate Polycarbonate?

Of course, this is one of the most critical technique to undertake.

Therefore, you got to have all the reasons for doing it before even thinking of how to start it.

Different people often laminate polycarbonate or rather go for laminated polycarbonate materials for numerous reasons.

In this section, I want us to look at some of the key reasons for laminating this particular type of plastic material.

Some of such reasons include the following;

· To easily combine characteristics of several materials in a single pane

Well, this is one of the key reasons why many people often undertake the process of laminating polycarbonate materials.

You see, in many instances, you’ll find that your application requires the final product to attain some particular properties.

These characteristics may vary from one application to the other.

And some of them may include resistance, anti-glare, anti-reflection and anti-scratch properties among others.

Scratch resistant polycarbonate sheet

Scratch-resistant polycarbonate sheet

But then, incorporating such properties especially on finished product can tend to be relatively difficult.

So one of the easiest ways that you can use of course is by laminating the different materials in a single pane.

In many instances, this becomes a success, and the end product attains all the necessary characteristics through lamination.

· To enhance the resistance of the material to breakage

It is also another reason why laminating polycarbonate would be essential.

Well, we all know that polycarbonate is one of the most robust materials you can ever get around.

And it is the main reason nowadays; it’s used in almost different relevant applications.

But then, the strength might be relative.

And in some instances, the strength has to be extreme as a way of sustaining particular projects or applications.

Laminating this material is an ideal way of improving its resistance to breakage.

Of course while at it, you have to use different ingredients for the material to achieve this characteristic.

What happens though, is that you have to ensure that the combination of these ingredients is suitable before laminating the sheet.

Polycarbonate ballistic face shield

Polycarbonate ballistic face shield

So the bottom line here is that polycarbonate laminating is essential when it comes to enhancing the resistance of a material to breakage.

And it’s in such instances that you’ll find perhaps the laminate is what breaks but the actual material remains still.

Many people, therefore, deem it ideal to laminate the polycarbonates before using them in various applications due to such characteristic.

· To improve the attractiveness of the finished material

If you’re keen enough, you’ll notice that most of the laminated polycarbonate materials tend to have some appealing features.

What happens is that before laminating, the material is seemingly plain.

And there are specific applications which require more than the basic characteristics of the polycarbonate material such as durability.

IP Camera lenses

IP Camera lenses

So for the sheet to have an attractive look, in some instances, you’ll need to laminate it using specific types of laminates.

So that by the time you complete the process, you’ll be able to have a bright and striking finish that is appealing to the eye.

And in all these, you’ll probably increase the chances of making the material sellable or have high demand in the market.

· To increase clarity of the polycarbonate

This is also the other fundamental reason why you need to or why many people opt for laminating polycarbonate material.

You see, most of the polycarbonate applications are often those that expose it to various physical and environmental hazards.

Polycarbonate panel

Polycarbonate panel

So other than strength, you also require the sheet to maintain or enhance its clarity, of course depending on the application.

Therefore, laminating helps by providing a protective layer which guarantees the clarity of the material especially those for optical applications.

For example, a vehicle’s windscreen requires a high level of clarity irrespective of the prevailing weather condition.

And when you laminate it, it becomes it increases chances of maintaining the clarity throughout.

The main reason here is that the laminate, which forms the outer layer protects the polycarbonate sheet from a wide range of damaging effects.

It prevents it from scratches, which ordinarily destroys clarity.

It also protects the surface from glare, unreasonable reflection as well as other weather conditions.

· To control extreme weather conditions

In many instances, you’ll notice that several areas all over the world tend to experience different types of extreme weather conditions from time to time.

Using a laminated polycarbonate would be helpful in such instances because it makes it possible for you to control such conditions.

For example, in high temperatures, the laminated polycarbonates can easily cool down the temperatures accordingly.

While on it, this type of technology also helps to prevent other aspects of weather such as glare among others.

The substances for polycarbonate laminating are essential because they also help in enhancing UV resistance.

This, of course, is vital because it allows you and other people to have good health.

· To minimize sound transmission

Another compelling reason why you would need to laminate polycarbonate sheet is to reduce transmission of sound in the vicinity.

You see, there are these establishments in areas that seem to be somehow busy and experience colossal traffic.

For example, the business premises along the busy streets are affected most of the time because of the noise within the surrounding.

Polycarbonate panel sound barrier

 Polycarbonate sound barrier

Also, areas like a restaurant and other entertainment joints that play loud music would always want to restrict the noise within the premises.

Now the more relaxed way of attaining this and at the same time maintaining the classy look of the premises is by using laminated polycarbonate.

Most of the substances you use for laminating such sheets prevent excessive noise from getting out or into such establishments.

And this is ideal because, for a restaurant or entertainment joint, it prevents inconveniencing other people within the premises.

So these are some of the key reasons why you would necessarily need to laminate polycarbonate.

Of course, as you may also know, in some instances, you’ll need to laminate polycarbonate for other various reasons.

In fact, it’s a particular application that determines the necessity of laminating a polycarbonate material.

In the next section though, I want us to look at the major types of laminating polycarbonate material.

Types of Polycarbonate Laminating Techniques

The truth of the matter is that laminating polycarbonate is one of the most sophisticated processes you can ever think of.

You see, what happens is that you have to use the best technique to ensure that you obtain the best results from this process.

Types of polycarbonate techniques also tend to vary depending on one application to the other.

However, in this section, we want to look at the two major types of undertaking this technique.

The significance of this is to enable you to know them in details and to give you an idea of what to expect.

So let’s go straightaway and discuss more these two major types;

1. Polyvinyl butyl polycarbonate lamination

Well, this is arguably one of the most common and preferable kinds of laminating polycarbonate technique.

In many instances, you’ll find it referred as PVB, and it is common in polycarbonate applications which require optical clarity and strong binding.

PVB is also ideal for laminating applications that require adhesion to several surfaces, those that need flexibility as well as toughness.

Generally, PVB polycarbonate lamination entails the use of two or more sheets bonded together with one or more layer of PVB ingredient.

Polycarbonate lamination

Polcarbonate lamination

So it happens that you sandwich the PVB layer between the glazing sheets.

In that process, you’ll need to use somewhat sophisticated equipment where the assembly shall pass through nip rollers to expel air bubbles.

The essence in such instances is to ensure that there is ideal contact between the layers.

This type of lamination, in general, integrates several elements of PVB ingredients with the layers of the polycarbonate sheet to form a strong bond.

And by the end of the process, you’ll have a laminated polycarbonate that is strong and adheres to the interlayer.

The benefit of using this technique is that the interlayer functions to hand out impact forces through a greater area of polycarbonate pane.

Secondly, the interlayer also functions to bind the resultant shard should the polycarbonate material end up breaking.

And lastly, the interlayer, which apparently is viscoelastic goes through plastic deformation during impact hence absorbing energy.

2. Resin polycarbonate lamination

This is also the other common type of lamination technique for most of polycarbonates sheets.

Ideally, it involves the use of a resin substance which is a solid or somewhat viscous element of a plant that is convertible into polymers.

The design of this substance is to allow it to remain clear even when catalyzed.

Laminating polycarbonate using a resin also has an adhesion promoter which apparently dormant until the catalyst’s adhesion.

You also need to know that this adhesive is a specially adapted.

The use of resin to laminate polycarbonate is vital because if a wide range of reasons;

First is that this substance tends to hold reinforcement material together as it allows it to conform to the desired shape.

This substance also helps to transfer mechanical properties from fiber bundles across the entire part.

Polycarbonate shield

Polycarbonate shield

One of the key properties of this substance is that it has an excellent viscosity which makes it easy to use and allowing fast air bubble release.

The other good thing with resin polycarbonate lamination is that it enables you to laminate the sheets at cost-effective rates.

And by the way, you do not need expensive machinery to produce laminated polycarbonate using this particular technique.

The other good thing with resin polycarbonate lamination is that it can protect the sheet from bad weather and other natural disasters.

Well, and that could be the reason this particular type of lamination is preferred for application in areas that experience extreme weather conditions.

Common Problems in Polycarbonate Laminating Process

Listen, like I did mention before, laminating is a technique that requires quite a lot of experience and knowledge.

But that notwithstanding, in most instances, several challenges tend to arise whenever you’re laminating polycarbonate.

Of course, it depends on quite a lot of factors because every problem possibly arises due to different aspects.

Riot face shield

Riot face shield

Nonetheless, let’s briefly look at some of the common problems you’re likely to experience in the polycarbonate laminating process.

a) Bubbling

When laminating polycarbonate, you’ll likely experience a few laminator issues that look like bubbles under the film.

Well, what you need to know is that the cause of such bubbles are quite many and could be as a result of the failure of adhesive to bond appropriately.

Therefore, whenever you’re laminating this material, you need to be observant of the bubbling issue and try to avoid it as much as possible.

b) Wrinkling

The most common cause of wrinkling issue is insufficient supply roll tension.

What often happens is that each laminator requires a particular amount of resistance to the unwinding supply of the rolls.

In most instances, when you’re laminating thinner polycarbonate sheets, you’ll need less tension.

And thicker films will require more tension.

c) Orange peel

This refers to the extremely fine wrinkles or waves that you’re likely to find in the laminate.

In most instances, the cause of this effects is always used of excessive heat when laminating polycarbonate.

What you need in this instance to avoid such effects is merely adjusting the temperature to an ideal setting.

You also need to know that orange peel can as well arise as a result of laminating sheets with a lot of solvent residues.

d) Waving, blistering and dimpling

The main cause of these effects is the presence of natural moisture in the material which makes the item to swell closer to the laminate.

Using too much heat dries out the moisture, but swollen areas distort the material from lying flat.

Insufficient tension, as well as uneven pressure, can also lead occurrence of such effects during the laminating process.

e) Static electricity

It is also a common issue that is likely to arise as you laminate polycarbonate.

At times, it could be difficult to prevent it, but you can easily keep it under control by taking different precautions.

And it is a significant problem, especially when laminating lighter polycarbonate sheets. So you have to devise methods of alleviating this problem effectively.

One tip of preventing this challenge is removing or neutralizing it by induction.

The other precautionary method is by grounding all your plant machinery and other related equipment.

The essence of this is to help in draining off extremely high static electricity charges on both sides of static-laden material.

f) Repeating marks

Well, this is always a major problem that arises typically when there is something on the roll.

That something could be an object such as a piece of paper, or in other instances, a scrap of film.

So an ideal way of dealing with this is by cleaning the rolls appropriately to remove such residues.

In the next section, we want to look at some of the fundamental elements that you need to consider when laminating polycarbonate material.

Key Considerations in Polycarbonate Laminating

Before you even think of laminating any polycarbonate sheet, it is always vital to ensure that you consider a number of factors.

You see, such factors are what ideally determine the success, failure, and efficiency of the entire process.

Laminating plastic

 Laminating plastic

Therefore, let’s go straightaway to the point and have an overview of the factors that you have to consider when laminating polycarbonate.

§ Film size

Well, this primarily refers to the size of the polycarbonate sheet regarding thickness.

You see, most of the time, it’s the thickness of the film size that determines the type, technique as well as machinery to use in laminating the sheet.

You have to know the elements which you require to attain best results when laminating a particular size of the polycarbonate sheet.

§ Preset lamination speed and pressure

This is also another fundamental aspect that you have to consider when you’re laminating polycarbonate.

What happens is that when you’re laminating this sheet, you have to use some of the sophisticated machines.

So when using such machines, you need to understand how to operate them especially by setting the ideal speed and pressure.

These two aspects have a critical impact on the overall results of the laminate that you’ll have on your polycarbonate.

§ Lamination rollers

When dealing with laminating machines, you also need to be aware of the fact that the rollers play a significant role in attaining best results.

For that matter, you have to figure out the best lamination rollers that suit your needs at that particular moment.

Lamination rollers come in different types as well as sizes.

Therefore, you need to determine the appropriate types that guarantee the best results.

§ Forced air cooling

Well, this is another critical factor when it comes to polycarbonate laminating.

The thing is, this process undergoes several elements, of course, depending on the type of technique that you use.

So after laminating the sheet, it has to cool down appropriately as a way of preventing a myriad of issues from arising.

Still, you have to understand how various operations are revolving around the processes of polycarbonate laminating.

§ Type of laminator

Of course, this is the other crucial factor that you have to consider when laminating polycarbonate sheet.

Presently, you’ll realize that several types of laminating machines are available in the market.

And by the way, this makes it so difficult for you to choose the appropriate one.

You need to be specific and determine the exact type of laminator that you require for your laminating needs.

In fact, you need to know the specifications of the particular laminator before shopping for one.

§ Application of the material

This is the other element that you must determine when laminating polycarbonate.

What happens is that different laminated polycarbonate materials are used in a wide range of applications.

And some applications require a specific type of laminate to work effectively.

So in other words, the type of material that you are laminating is dependent on the application.

For that matter, you have to find out all the concepts revolving around the application of laminated sheet before thinking of laminating one.

So these are the key considerations that you have to ensure you look into when laminating polycarbonate.

Factors to Consider when Buying Polycarbonate Lamination Machine

Even so, it would also be ideal to know some of the elements to consider when shopping for a polycarbonate lamination machine.

By the way, this is vital because it somehow determines the efficiency and effectiveness of carrying out this task.

Plastic laminating machine

Plastic laminating machine

So in brief, I want us to look at some of the vital aspects to look into when shopping for an ideal polycarbonate laminating machine.

1. Variable speed

Speed is a critical element when it comes to laminating polycarbonate material.

In many instances, you’ll notice that there will always be the need to keep on adjusting the speed accordingly during the lamination process.

So it means that you must determine the variable speed of the equipment and ensure that it suits your needs.

Of course, the variable speed of such equipment does vary from one to the other depending on numerous factors.

Nonetheless, it remains a key concern that you must look into when buying this machine.

2. Digital thermometer

Well, the essence of a thermometer in this instance is to help in determining the temperature of the machine.

But then, it needs to be digital to enhance accuracy and also enable you to figure out the readings easily.

3. Controls

It’s also imperative to ensure that you’re looking into the particular control system of the machine before buying it.

What normally happens is that different laminating machines have different control systems.

So it means that you’ll always have to know how to use them given that these are some of the important elements in determining various parameters.

You have to take your time and study all the controls to ensure that it becomes easy for you to operate it.

4. Slitters

Any ideal polycarbonate laminating machine should have slitters.

But then, it is the type of slitter that determines whether or not the final product will meet the results.

In other words, you always need to ensure that the slitters are suitable for the particular polycarbonate material you’ll be laminating.

Otherwise, you’ll in the most instance be experiencing some of the problems such as the ones that I did list in this guide earlier.

5. Size

The size of the laminating machine also matters to a significant extent.

You see, it happens that you’ll always want to laminate different sizes of polycarbonate sheets.

So it is expected to have a sizeable machine that fits your project.

Incidentally, you also need to look at the use.

If you’re laminating polycarbonate for DIY projects, you don’t necessarily need to get a bigger laminating device.

6. Usability

It is also vital to ensure that the machine you’re selecting is easy to use.

The significance of this is that it enhances efficiency is such a manner that you’ll not be seeking help all the time you’re using it.

Again, the usability of this machine increases the chances of attaining better or desirable results most of the time.

7. Safety features

Now, laminating polycarbonate involves quite a number of risks given the involvement of several hazardous materials.

Therefore, you need to get a machine that allows you to control all the parameters quickly and effectively.

So such safety features enable you to take control in case of an unlikely event during the lamination process.

But then, you also need to ensure that you wear all the necessary protective gears.

Such gears always safeguard you from injuries in case of a mishap when using the machine to laminate the sheet.


As you can see from this guide, polycarbonate laminating incorporates quite a number of elements that you probably did not know.

Hopefully, though, the information that you have received herein has enabled you to know the different aspects which you ought to have known.

The bottom line nonetheless, is that polycarbonate laminating is an ideal technology for numerous applications.

For instance, automotive windscreens and other several areas in the construction industry.

So what you need to do is making sure that you acquire the necessary elements such as tools, materials, and equipment.

And then, you also ensure that you carry out the process in accordingly, bearing in mind the necessary safety precautions.

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