Polycarbonate vs. Acrylic for Promo Products: The Ultimate Guide

Polycarbonate vs. Acrylic: which material suit your promotional products, really? When creating eye-catching promotional products, selecting suitable material is crucial. Two popular choices are polycarbonate and acrylic. Both materials offer unique properties and advantages, making them ideal for various applications.

Though both have unique characteristics, it’s hard to decide which one really fit for making effective promotional products. In this blog post, we will delve into the differences between polycarbonate and acrylic, explore their manufacturing processes, and highlight examples of products made from each material.

Polycarbonate vs. Acrylic

Polycarbonate and acrylic are types of plastic used for making promotional products. Polycarbonate, a thermoplastic polymer, stands out for its exceptional strength and versatility. With high impact resistance and transparency akin to glass, it finds applications in various industries.

Meanwhile, Acrylic, known as polymethyl methacrylate (PMMA), boasts exceptional transparency, weather resistance, and a wide range of colours. It is widely used in applications that require optical clarity and aesthetic appeal. Here’s a brief comparison between these two:

1. Durability

Durability is crucial for promotional products, as they must withstand everyday use and leave a lasting impact. Polycarbonate stands out in this regard, renowned for its exceptional strength and toughness. It is highly resistant to impact, making it an excellent choice for drinkware, phone cases, and outdoor promotional products.

Acrylic, while reasonably durable, is not as robust as polycarbonate. It is better suited for indoor applications such as signage, displays, and decorative accessories.

2. Transparency and Clarity

Promotional products often use visual appeal to attract attention and convey a brand’s message effectively. Acrylic shines in this aspect, offering excellent transparency and clarity. Its optical properties allow for vibrant and eye-catching designs, making it an ideal choice for products that rely on intricate graphics or detailed artwork.

Polycarbonate, while transparent, may exhibit slight haziness in comparison. However, advancements in polycarbonate technology have considerably improved its clarity, narrowing the gap between the two materials.

3. Impact Resistance

Considering the potential mishandling of promotional products, impact resistance is a vital factor to consider. Polycarbonate’s outstanding impact resistance sets it apart from acrylic. It can endure high impacts without cracking or breaking, making it suitable for products prone to rough handling or accidental drops.

While moderately impact-resistant, acrylic is more susceptible to shattering or cracking under extreme force. Thus, polycarbonate is the go-to option if your promotional items are likely to face rigorous usage or outdoor environments.

4. Flexibility and Formability

The flexibility and formability of the material play a crucial role in shaping promotional products with unique designs. Acrylic boasts higher levels of flexibility, making it easy to mould and shape into various forms. This versatility allows for creatingf curved or intricate items like keychains, pens, or decorative accessories.

On the other hand, polycarbonate, while less flexible, retains its shape and rigidity. It excels in applications that require structural stability and sturdiness, such as displays or protective cases.

5. Cost Considerations

Budgetary constraints often play a significant role in material selection for promotional products. Acrylic is generally more cost-effective than polycarbonate, making it an attractive choice for large-scale campaigns or situations where cost efficiency is paramount.

Polycarbonate, however, can be pricier due to its superior strength and durability. Nevertheless, considering the extended lifespan and long-term value of polycarbonate products, the initial investment can prove worthwhile in terms of overall durability and brand visibility.

Examples of Products Made of Polycarbonate and Acrylic

Polycarbonate 

Made from solid polycarbonate material, our canopy structure is high quality and comes in different colours and surface designs to match your style and functionality requirements.

The table is made of eco-friendly Polycarbonate, chrome-plated iron, and glass. This product will be a great outdoor promotional item for drink companies to market their brand and allow your customers to have fun simultaneously!

The frame of this custom-branded merchandise is made from Thermoplastic Polyurethane (TPU) which is long-lasting, while the lenses are made from Polycarbonate film, which is resistant to any scratch and has an anti-fog coating.

Acrylic

This custom acrylic memo board can be a staple marketing display for your everyday business. The merchandise comes in a box with the memo board, a base with LED lights and a pen.

This acrylic display holder for protective products is great for retail stores, hospitals, schools, and places people frequently visit. This item provides a convenient location to keep all the necessary things to protect employees, patients, clients, and customers.

With the holidays coming, these LED light box signs are great for leveraging during the festive season! To reinforce finer brand remembrance, brands can use these to attract attention further.

Polycarbonate vs. Acrylic: The Manufacturing Process

Polycarbonate and acrylic are two widely used materials in the world of plastics, each with unique properties and manufacturing processes.

Polycarbonate Manufacturing Process

1. Polymerization: Polycarbonate is typically produced through a reaction called the interfacial polymerization process. This process involves the reaction of bisphenol A (BPA) and phosgene (COCl2) in a solvent, forming a polycarbonate polymer. The reaction occurs in the presence of a catalyst and at controlled temperature and pressure conditions.

2. Purification: The crude polycarbonate product is purified after the polymerisation reaction to remove impurities and residual monomers. This step ensures that the polycarbonate meets the required quality standards.

3. Melting and Extrusion: The purified polycarbonate is then melted and extruded into the desired form, such as sheets or pellets. The melting process is carried out in extruders, where the polymer is heated to a molten state and then forced through a die to form the desired shape. Extrusion allows for efficient mass production and enables the material to be easily moulded into various forms.

4. Injection Moulding: Injection moulding is another standard method used to manufacture polycarbonate products. The molten polycarbonate is injected under high pressure into a mould cavity during this process. The material quickly cools and solidifies, taking the shape of the mould. Injection moulding is preferred for producing complex shapes and precise dimensions.

Acrylic Manufacturing Process

1. Polymerization: Acrylic is typically produced through bulk polymerization. This process involves the polymerization of methyl methacrylate (MMA) monomers using heat or chemical initiators. The reaction forms a PMMA resin, the base material for acrylic products.

2. Extrusion or Casting: The PMMA resin can be processed through different methods depending on the desired product after polymerisation. Extrusion is commonly used for creating acrylic sheets. The resin is melted and forced through a die, which gives the material a specific thickness and shape. On the other hand, casting produces intricate or three-dimensional acrylic products. The resin is poured into a mould and allowed to solidify, taking the shape of the mould.

3. Finishing: Once the desired shape is obtained, the acrylic product often undergoes finishing processes to enhance its visual appeal and clarity. This may include polishing, buffing, or flame polishing to remove surface imperfections and improve the material’s transparency.

Are you looking for more sustainable materials for your promotional products? ODM highly supports sustainable marketing. Thus we always come up with more eco-friendly alternatives. Take a look at these options below:

Pineapple vegan leather is a non-woven textile made from the fibres of pineapple leaves mixed with polylactic acid (PLA) and petroleum-based resins to form a leather-like texture. It’s available in various colours and is primarily used nowadays in the fashion and design industry.

Bagasse is a waste product of sugarcane after the farmers squeeze the stalks. It’s a cellulose fibre that is initially discarded, thus its name bagasse, an Italian word that means trash or garbage. While the name also extends to some plant product waste, it’s exclusively used for sugarcane offshoots nowadays.

Grass straws are made from a grey sedge grass species called Lepironia Articulata. Locally called “Co Bang”, it grows around the Mekong Delta Region in the southwestern region of Vietnam. It has a hollow stem that makes it ideal for sipping drinks.

Post-Consumer Recycled(PCR) material is created by consumers after a product has reached the end of its use. This material is dumped into the landfill and processed to make other useful commodities.

In a Nutshell

Polycarbonate and acrylic are two remarkable materials with distinct advantages in manufacturing. Polycarbonate boasts exceptional strength and transparency, ideal for safety equipment, automotive components, and electronic devices. On the other hand, acrylic offers unparalleled optical clarity and versatility, making it a preferred choice for signage, lighting fixtures, and home décor.

By understanding these materials’ unique characteristics and manufacturing processes, manufacturers can make informed decisions, ensuring the production of high-quality products that meet specific requirements.

Create Promotional Products That Stand Out!

ODM Group is a leading provider of creative promotional solutions that can help businesses elevate marketing campaigns and captivate target audiences. We offer an extensive range of promotional products to cater to diverse marketing needs.

From traditional items like pens, mugs, and keychains to more unconventional options such as tech gadgets, eco-friendly products, and custom-designed merchandise, ODM Group has a wide array of choices to suit every brand’s personality and target audience.

Moreover, we provide exceptional services such as sketch design, prototyping, quality control, and manufacturing. Learn more about how we can help you bring your marketing to the next level. Send us an email to get a detailed quote.

Frequently Asked Questions

What are the advantages of using polycarbonate and acrylic for promotional products?

Polycarbonate and acrylic offer several advantages for promotional products. Both materials are highly durable, resistant to impact, and have excellent optical clarity. Polycarbonate is known for its exceptional strength, making it suitable for products that require toughness and shatter resistance. Acrylic, on the other hand, offers superior transparency and can be easily shaped into various forms. Both materials can be customized with branding, and their versatility allows for a wide range of creative designs and finishes.

Can polycarbonate and acrylic be personalized with logos and artwork?

Yes, both polycarbonate and acrylic can be personalized with logos, artwork, and branding elements. These materials offer excellent printing and engraving surfaces, allowing for the application of custom designs. Logos and artwork can be applied through techniques such as screen printing, pad printing, or laser engraving. Additionally, both materials can be produced in different colours and finishes to match specific branding requirements, ensuring a cohesive and visually appealing promotional product.

Are there any limitations or considerations when using polycarbonate and acrylic for promotional products?

While polycarbonate and acrylic offer numerous benefits, there are a few considerations to keep in mind. Firstly, although both materials are highly durable, polycarbonate tends to be more impact-resistant than acrylic. Therefore, if the product will undergo frequent rough handling or potential impacts, polycarbonate may be the preferable choice. Secondly, acrylic can be more prone to scratching compared to polycarbonate, so it is essential to consider the product's intended use and take appropriate measures to minimize surface damage. Lastly, extreme heat can affect both materials, so it's important to avoid exposing them to high temperatures.

What to Read Next?

2023-06-20T13:22:49+08:00

Share This Story, Choose Your Platform!

Go to Top