— Polycarbonate / Lexan

Polycarbonate for Tough Sign Faces and Lighted Signs

Polycarbonate is a tough transparent thermoplastic used for sign faces, lighting diffusers, protective panels, and applications where impact resistance matters. LEXAN is one of the best-known polycarbonate brands and includes sheet grades made specifically for signs and LED lighting.

Material

Solid Polycarbonate Sheet

Common Sign Range

About 3–6 mm

Environment

Indoor & Outdoor by Grade

Graphics

Second-Surface · Print · Vinyl

— Overview

What Is Polycarbonate?

Polycarbonate is a clear or translucent engineering plastic known for high impact resistance and good light transmission.

Sign-grade polycarbonate is used where a plastic face needs to tolerate handling, weather, or impact better than a more brittle sheet. Manufacturers also produce white, diffusing, textured, and UV-resistant grades for illuminated signs and lighting applications.

Illuminated Sign Faces White or diffusing sheet for cabinets, light boxes, and LED-backed sign faces.

Protective Sign Covers Clear tough panels where impact or vandal resistance matters.

Second-Surface Graphics Graphics applied or printed behind clear sheet for added face protection.

Lighting Components Diffusers and covers used to hide light sources and spread illumination.

— Sign Grades

Polycarbonate Thickness and Sign-Specific Sheet

Polycarbonate sheet is available across a wide gauge range. Sign-grade LEXAN products are commonly offered around 0.093 to 0.236 inch, or roughly 2.4 to 6 mm, with specialty lighting and exterior grades available outside that range.

2.4–3 mm

Thin Sign Face
Useful for supported sign faces, protective covers, and compact lighting applications.

Support, cabinet dimensions, and forming method still matter.

4–4.5 mm

Heavier Sign Sheet
Adds stiffness for larger faces and more demanding assemblies.

Often used where impact resistance and panel stability are both important.

6 mm

Thicker Polycarbonate
More material depth for protective panels and larger fabricated components.

Weight, mounting, and thermal movement become more important as thickness increases.

— Material Comparison

Polycarbonate vs Acrylic for Signs

Polycarbonate

Acrylic

Impact
Very high impact resistance; useful for protective and demanding sign applications.

Impact
More brittle than polycarbonate but widely used for polished sign faces and letters.

Surface
Tough substrate, though standard sheet can scratch and may need the right coating or care.

Surface
Harder surface feel and excellent optical appearance.

Sign Fit
Strong choice for cabinets, diffusers, protective covers, and exposed faces.

Sign Fit
Strong choice for dimensional letters, polished panels, office signs, and clear decorative work.

— Graphics & Fabrication

How Polycarbonate Is Used in Sign Production

Polycarbonate can be cut, drilled, routed, formed, decorated, and printed when the sheet grade and process are compatible. Sign-face grades may also be made for second-surface decoration so the graphics sit behind the clear face.

Second-Surface Decoration Printing or applied graphics placed behind clear sheet for a protected finished face.

Direct Graphics Compatible sheets can receive print, paint, or applied vinyl.

Thermoforming Polycarbonate can be heat formed for shaped faces and fabricated sign parts.

LED Diffusion Specialty white and diffusing grades help hide individual light sources.

— Choosing the Material

When Polycarbonate Is the Right Choice

Consider another material when

On This Guide

Quick Facts

Material

Polycarbonate

Common Gauges

LEXAN is one major brand

Environment

High Impact Resistance

Common Uses

Sign Faces · Diffusers · Covers

Related Materials

Not Sure Which Material Fits?

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