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Polycarbonate thermoforming

Polycarbonate thermoforming

Polycarbonate is the material for parts that must survive impact, heat and high voltage. Indu Thermoformers forms PC and halogen-free flame-retardant PC — UL 94 V-0 from 0.25 mm with CTI 600 for high-voltage insulation — from sheet extruded in-house for EV, electrical, rail and glazing applications.

Extreme impact & heatFR PC — UL 94 V-0CTI 600 insulationOptically clear grades
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When only polycarbonate will do

PC combines the highest impact resistance of any thermoforming plastic with heat resistance (Vicat ~138 °C for FR grades), optical clarity and — critically — electrical properties that make it the default for EV and electrical parts. It demands careful drying and higher forming temperatures than ABS, which our process is set up for.

Flame-retardant PC for EV, electrical and rail

Our Shield FR PC is a native halogen-free grade: UL 94 V-0 verified from 0.25 mm, VTM-0 for thin films, with a premium CTI of 600 (the highest tracking-resistance class) and 38 kV/mm dielectric strength. That combination is why battery makers specify it for CCS trays and module covers, and why it suits switchgear barriers, power-electronics insulation and rail HVAC ducting. Optically clear PC grades cover skylights, guards and face shields.

Parts we thermoform in polycarbonate

EV battery CCS trays & module coversBESS & power-electronics insulationElectrical cabinet & switchgear barriersMachine guards & sight glassesSkylights & transparent panelsFace shields & protective gearRail HVAC duct covers (HL3)Semiconductor equipment components

PC grades & datasheets

Shield FR PC (V-0, CTI 600)PC General Purpose (clear glazing)PC Tuff (hard-coated)

Full technical specifications for each grade are below.

Grade specifications & datasheets

Typical properties as printed on the StellarEx technical datasheet for each grade — download the full TDS or request a quote.

Fire retardantPolycarbonate

StellarEx Shield FR PC

Fire-retardant polycarbonate — halogen-free, UL 94 V-0 / VTM-0, high-voltage insulation grade with CTI 600.

  • UL 94 V-0 verified at 0.25 mm and above
  • VTM-0 rated for thin-film applications
  • Native halogen-free formulation
  • High-voltage electrical insulation grade
  • High thermal performance — Vicat 138 °C

Applications: EV battery CCS trays · cell-contacting systems · BESS modules · high-voltage compartment liners · Power electronics insulation components · Electrical cabinets · switchgear barriers · Rail HVAC duct covers · flame-rated airflow parts

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Typical properties (as printed on TDS)

Density1.20 g/cm³ISO 1183
Tensile strength60 MPaISO 527
Flexural strength91 MPaISO 178
Vicat softening temp138 °CISO 306
Dielectric strength38 kV/mmIEC 60243
CTI (premium)600IEC 60112
Rating ≥ 0.25 mmV-0UL 94

Thickness: 0.25 – 8.0 mm (V-0 ≥ 0.25 mm)  ·  Width: wide-web · custom

GlazingPolycarbonate

StellarEx PC General Purpose

General-purpose polycarbonate — clear, virtually unbreakable glazing and fabrication grade with high heat resistance (Vicat 145 °C).

  • Virtually unbreakable — unnotched Izod does not break
  • High heat resistance — Vicat 145 °C
  • Clear glazing — 84–87% light transmission
  • UL 94 HB · EN 13501-1 B-s1,d0 · UL 746B RTI 130 °C
  • Halogen-free · RoHS · REACH compliant

Applications: Skylights, roof domes & barrel-vault rooflights · Machine guards & safety screens · Glazing, light covers & fabricated panels · Electrical & indoor engineering components · Deep-drawn covers & enclosures

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Typical properties (as printed on TDS)

Density1.20 g/cm³ISO 1183
Yield stress> 60 MPaISO 527
Tensile modulus2300 MPaISO 527
Flexural strength90 MPaISO 178
Notched Izod70 kJ/m²ISO 180
Vicat softening (B/120)145 °CISO 306
HDT @ 1.8 MPa127 °CISO 75-2

Thickness: 1 – 12 mm  ·  Width: wide-web · custom

Hard-coatPolycarbonate

StellarEx PC Tuff

Hard-coated polycarbonate — mar- and abrasion-resistant, optically clear (92% transmission) glazing grade for demanding flat applications.

  • One-side hard-coat — mar & abrasion-resistant surface
  • Exceptional optical clarity — 92% transmission
  • UV-protected surface for outdoor glazing
  • Tough, ductile, high-impact polycarbonate
  • Flat applications; laminates with glass for security glazing

Applications: Transport & vehicle glazing · Machine guards & safety screens · Bullet-resistant / security glazing (laminated) · Signage, displays & light covers · Protective screens & barriers

Download TDSGet a quote →

Typical properties (as printed on TDS)

Density1.20 g/cm³ISO 1183
Yield stress> 60 MPaISO 527
Tensile modulus2300 MPaISO 527
Strain @ break> 100 %ISO 527
Vicat softening (B/120)145 °CISO 306
HDT @ 1.8 MPa127 °CISO 75-2
Light transmission @ 2 mm92 %ASTM D1003

Thickness: 1 – 12 mm  ·  Width: wide-web · custom

See all StellarEx grades on the Materials & grades page.

Why Indu for polycarbonate thermoforming

In-house sheet extrusion

We extrude the sheet we form — grade, colour and thickness controlled from the pellet, with no outside vendor in the loop.

Largest bed in India

Thin- and thick-gauge lines, including the largest thermoforming bed in the country for oversized parts.

Tooling in 2–4 weeks

Moulds and trim fixtures designed and cut in-house on 5-axis CNC — fast, and cheap to revise.

ISO 9001 & full docs

8-gate inspection with COA, MTC, FAIR and PPAP-level documentation on request.

Frequently asked questions

Can polycarbonate be thermoformed?

Yes — PC thermoforms well but must be dried before forming and run at higher temperatures than ABS or HIPS. We handle both, and because we extrude the sheet we control moisture and grade from the start.

Why choose FR polycarbonate for EV battery parts?

Battery parts need flame retardance and high-voltage insulation. Our Shield FR PC is UL 94 V-0, halogen-free, with CTI 600 and 38 kV/mm dielectric strength — allowing tighter creepage distances between conductors while meeting insulation standards.

Is clear polycarbonate available for glazing and guards?

Yes — optically clear PC grades for skylights, machine guards, sight windows and face shields, combining transparency with the impact resistance PC is known for.

Explore more

PC-FR V0 Battery Insulation →EV & Battery Components →Shield FR PC Datasheet →Machine Covers & Enclosures →

Let’s build it

Need a polycarbonate part?

Send your drawing — we reply with the right PC or FR PC grade, tooling and a costed quote, usually within 24 hours.

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ISO 9001:2015 certified · Most quotes back within 24 hours