Polycarbonate Injection Molding
Production-grade PC parts for impact strength, heat resistance, and optical clarity—supported from DFM to stable mass production.
ISO 9001:2015 | ISO 13485 | IATF 16949:2016 | AS9100D
Polycarbonate Injection Molding Services
Get production-ready polycarbonate parts built for impact strength, heat resistance, and consistent optical appearance.
We support runs from early DFM through tooling, sampling, and repeatable mass production.
Polycarbonate (PC) Injection Molding Capabilities
| Capability | Details |
|---|---|
|
Press tonnage |
50–1,300T |
|
Max part size |
Up to 600 mm (part-dependent) |
|
Typical tolerance |
±0.05 mm (typical) |
|
Precision tolerance (CTQ features) |
Down to ±0.02 mm (geometry-dependent) |
|
Minimum wall guidance (PC) |
0.8–1.2 mm (thin-wall review required) |
|
Cosmetic / optical appearance |
Visible-surface control for clear/tinted parts, appearance spec alignment before tooling |
|
Surface finish / texture |
SPI A2–D3 and VDI 12–33 (as specified) |
|
PC grades supported |
Clear / tinted / UV-stabilized / flame-retardant (UL94) / PC-ABS (per requirement) |
|
Color matching |
Custom color matching (clear/tinted included) |
|
Warpage-sensitive control |
CTQ-driven control for datums, flatness-sensitive faces, sealing lands, and fit interfaces |
|
Inspection options |
CMM / dimensional reports, critical features check (on request) |
|
Documentation (optional) |
FAI / PPAP / CoC / material certs (customer requirement based) |
PC Grades Available at Kemal
We offer multiple grades of PC through our injection molding process, tailored for different applications:
- Lexan: Offered in unfilled and 20% glass-filled versions. Known for its high flame resistance and biocompatibility, making it ideal for healthcare components. Delivers an impact strength of up to 250 ft-lb/in.
- Makrolon: Versatile grade suited for general-purpose molding. Can be sterilized for medical use and withstands high temperatures (melt temperature: 280–320 °C / 536–608 °F). Available in both transparent and opaque colors.
- Hylex: High-flow, crystal-clear PC designed for intricate parts with demanding optical or cosmetic requirements.
- RTP: Supplied in unfilled and 10% glass-filled grades. Offers exceptional heat resistance (melt temperature: 288–316 °C / 550–600 °F) and extremely low moisture absorption (0.02%), ideal for precision parts in humid environments.
Typical Polycarbonate Parts We Mold
Clear Covers
cosmetic surface control · CTQ fit management · inspection optional
Lenses & Diffusers
appearance spec alignment · texture control · repeatable builds
Display Bezels
gap/flush control · visible-surface management · stable production
PC Housings
DFM risk notes · warpage-sensitive CTQs · repeatable assembly fit
Safety Shields
structural requirement support · edge/finish control · production consistency
Heat-Exposed Parts
grade selection support · dimensional stability control · repeatable runs
Polycarbonate Material Properties
| Property | Typical Value | Benefit for Your Application |
|---|---|---|
|
Density |
~1.2 g/cm³
|
Strong yet lightweight for easier handling and reduced shipping costs
|
|
Tensile Strength |
55–75 MPa |
Supports high load-bearing designs without deformation |
|
Impact Resistance |
Very high |
Resists cracking or breaking under heavy impact |
|
Heat Deflection Temperature |
125–135 °C |
Reliable performance in elevated temperature environments |
|
Light Transmission |
Up to 90% |
Excellent optical clarity for transparent parts |
|
UV Resistance |
With stabilizers |
Extended outdoor durability for sunlight-exposed components |
Need to confirm if PC is right for your part? Our engineering team can recommend the best material grade based on your design, environment, and budget.
Comprehensive Plastic Part Services
We provide early-stage design for manufacturability (DFM) analysis to optimize wall thickness, draft angles, and gate placement. This helps identify risks upfront and reduces costly mold changes later.
From single- to multi-cavity and hot runner molds, we build tooling that matches your production needs. Steel selection and surface finishes ensure durability and precision over the mold’s lifetime.
We offer standard molding, insert molding, and overmolding options. Each run is monitored with scientific process controls and full batch traceability to guarantee consistent results.
Choose from painting, pad printing, laser marking, and UV coating. ABS is especially well-suited for surface finishes, making it ideal for branded housings and visible parts.
Every part goes through strict IQC, IPQC, and OQC processes. We provide dimensional reports and compliance documentation to meet international standards.
From sub-assemblies to custom packaging, we streamline the final steps before shipping. Global logistics support ensures your parts arrive efficiently and ready to use.
Our Customers
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