Acrylic (Plexiglass) vs. Polycarbonate (Lexan) – A Comparison of Difference in Usage (2024)

We all want our homes to be glossy, gleaming, and refreshing like glasshouses. Isn’t it?

However, using glass all over the place might not be a great idea owing to the delicacy of the material.

Thanks to advanced technology (And of course, the pursuit of man to know more) we have discovered some great alternatives to glass. Plastic glass has overwhelmed the glass industry in a very short period of time. Acrylic sheets are now extensively used instead of glass in residential as well as commercial projects.

In the time of the rise of plastic glass, different types of plastic glass are also in the making. Two giants that are in close competition are; Acrylic and Lexan.

When considering plastic glass for a project, you would most probably find yourself making a choice between acrylic and polycarbonate. We are here to help you with the right decision. Here is a comprehensive guide on the difference between acrylic glass and Lexan. Let’s get into some groundwork first.

What is Plexiglass?

Acrylic glass, technically called polymethylmethacrylate (PMMA), is a transparent petroleum-based thermoplastic material. Due to its transparency and optical clarity, it serves as a great alternative to glass. It is widely used in the interior and construction industry.

Plexiglass vs Acrylic

Plexiglass vs Acrylic has been under debate for quite some time. Plexiglass and acrylic are nearly identical with no significant differences.

Acrylic is an abbreviation for the thermoplastic material Polymethyl methacrylate. It has outstanding strength, durability, and optical clarity. Due to these properties, acrylic is considered a prime alternative for glass.

On the other hand, plexiglass is a type of clear acrylic glass. It is actually one of the most popular acrylic glass brands. The first version of acrylic glass created in the early 20th century was branded as “Plexiglas”. With time, the brand name “plexiglass” became a universal term for acrylic. Now plexiglass and acrylic are used as synonymous terms. It won’t be wrong to say that both acrylic and plexiglass are essentially the same products with different names. However, there is just one difference to justify plexiglass vs acrylic – The manufacturing process!

Acrylic glass sheets are made through the continuous extrusion method. While plexiglass is manufactured through a casting cell method in which raw acrylic is fed between two panes of glass to make a cell. Plexiglass is also somewhat pricier than acrylic glass.

Plexiglass – The Manufacturing Process

Acrylic is actually a polymer of the plastic material methyl methacrylate. Therefore it is manufactured by the polymerization of methyl methacrylate in the presence of a catalyst. The polymers are then molded into sheets to get them ready for use.

What is Lexan?

Lexan or polycarbonate also comes under the category of plastic glass. It is referred to as polycarbonate due to multiple carbonate groups in its basic chemical structure. Lexan or polycarbonate has exceptionally high strength value and finds applications in bulletproofing and other such sturdy projects.

Lexan – The Manufacturing Process

Polycarbonate is manufactured by a chemical process between two chemical compounds Bisphenol A and carbonyl chloride. The product achieved as a result of the chemical reaction is thus cut into a variety of lengths and sizes to be used in different applications.

Plexiglass vs Lexan – The Contrast

Now that you are familiar with the basic concept and manufacturing process of acrylic as well as polycarbonate sheets, we are all set to dive deep into the material war. Let’s compare the properties of both and see which material suits your project requirements better.

Benefits of Plexiglass and Lexan Glass

Plexiglass and Lexan have taken over the glass industry due to the plethora of benefits they offer. High optical clarity, strength, transparency, and damage resistance are a few benefits that justify the high applications of Lexan and plexiglass in the commercial, residential and retail industry. You can have an at-a-glance view of the applications of Lexan and acrylic glass in the infographic attached below.

• Acrylic glass is heat bendable. You would need to use the machine and thermal power in order to shape the acrylic sheets in the way you want. Drilling the acrylic sheets can also result in cracking so it’s better to avoid it.
• Lexan is fully customizable and flexible. It can easily be cold-formed into any shape. You can bend it without heating and drill holes through lexan sheets without worrying about cracking or breaking them.

• Acrylic glass is resistant to most detergents, inorganic chemicals, and diluted acids but not very effective against harsh chemicals.
• Polycarbonate is immune to almost all chemicals. It can withstand harsh chemicals without getting damaged. That’s the reason why polycarbonate sheets are employed in industries as protectors.

Plexiglass and Lexan- Pros and Consof Installing

Acrylic glass is a profound material and provides many benefits over normal glass. Acrylic glass is almost 17 times stronger than standard glass which makes it a solid alternative to glass but Lexan is way stronger than even acrylic and costly option as well. Here’s some common benefits and demerits installing of acrylic and Lexan glass both which can help you to decide one according to your need.

In a word!

Both polycarbonate and plexiglass are stronger and more durable than glass. But considering all the properties, we can say that acrylic glass is a more commonly used material around us. Its cost-efficiency, strength, and grace make it the preferred choice for general use. On the other hand, polycarbonate is mostly used where a high-security level is the end goal.

Although polycarbonate has its own applications, you can never go wrong with acrylic for everyday use. Acrylic glass radiates the same elegance as glass so you can go around replacing the glass in your homes with plexiglass. It’s a complete win-win!