Technical Buyer's Guide
The Ultimate Guide to Lexan & Makrolon Polycarbonate in Canada
Everything you need to know about choosing, cutting, and installing architectural-grade polycarbonate sheets. From DIY projects to commercial applications.
What is Lexan & Makrolon Polycarbonate?
When professionals specify “Lexan” or “Makrolon,” they're referring to the two most recognized brand names in polycarbonate manufacturing. Lexan, manufactured by SABIC (formerly GE Plastics), and Makrolon, produced by Covestro (formerly Bayer MaterialScience), represent the gold standard for architectural-grade polycarbonate.
Both materials are thermoplastic polymers known for exceptional clarity, impact resistance, and versatility. While technically they're both polycarbonate, these brand names have become synonymous with quality — much like how “Kleenex” refers to facial tissue or “Band-Aid” means adhesive bandages.
Cold Bending vs Heat Forming Lexan
One of polycarbonate's most valuable properties is its ability to be formed into curves and shapes. Understanding the difference between cold bending and heat forming helps you choose the right approach for your project.
Cold Bending (No Heat Required)
Polycarbonate can be bent at room temperature to a minimum radius of approximately 175 times its thickness. This is called “cold forming” or “cold bending.”
- 3mm sheet: Minimum bend radius ~525mm (21")
- 6mm sheet: Minimum bend radius ~1050mm (41")
- No special equipment needed
- Sheet springs back when released unless secured
Best for: Barrel vault skylights, curved guards, gentle architectural curves, DIY projects.
Heat Forming (Thermoforming)
For tighter bends or complex shapes, polycarbonate must be heated to 150-180°C (300-350°F) and formed in a mold or over a mandrel.
- Achieves much tighter bend radii
- Shape is permanent after cooling
- Requires oven, heat gun, or line bender
- Pre-drying recommended to prevent bubbles
Best for: Machine guards with tight corners, custom enclosures, complex shapes, industrial applications.
Our Custom Cutting Service
At Plastics Canada, we specialize in precision custom cutting of polycarbonate sheets. Every piece is cut to your exact specifications with tolerances of +/- 1/8", ensuring a perfect fit for your project.
Precision Tolerance
Processing Time
Nationwide Shipping
CNC Plastic Cutting in Toronto
Our Toronto-area facility (Vaughan, Ontario) uses precision cutting equipment to ensure clean, accurate edges on every sheet. Whether you need a single panel or hundreds of custom-cut pieces, we deliver consistent quality with fast turnaround.
Fast Shipping Across Ontario and Canada
We ship daily from our Vaughan facility. Ontario customers typically receive orders within 2-3 business days, while other provinces can expect delivery within 4-7 business days depending on location. All panels are carefully packaged with corner protectors and wrapped to prevent scratches during transit.
Applications & Use Cases
Greenhouse & Agricultural
UV protected Makrolon for greenhouse roofing — Our UV-stabilized panels let beneficial light through while protecting plants and maintaining insulation. Shatterproof construction withstands hail and falling branches.
Window Replacement
Cut-to-size Lexan sheets for window replacement Canada — Perfect for basement windows, shed windows, and anywhere security and safety matter. Installs like glass but won't shatter.
DIY Projects
3mm Clear Polycarbonate 4-pack for DIY projects — Our value packs are perfect for hobbyists and makers. Great for workbench shields, hobby enclosures, robot covers, and custom fabrication.
Commercial & Industrial
Machine guards, safety barriers, sneeze guards, and protective enclosures. Impact resistance makes Lexan the go-to material for workplace safety applications.
Frequently Asked Questions
How durable is Lexan compared to glass?
Lexan polycarbonate is approximately 250 times more impact resistant than glass. It can withstand hammer blows, hail, and impacts that would shatter glass completely. Even when it does fail under extreme force, it cracks rather than shattering into dangerous shards.
Does Lexan yellow over time?
UV-stabilized Lexan and Makrolon sheets are formulated to resist yellowing for 10-20 years in outdoor applications. Our sheets include UV protection on one or both sides depending on the product. For best results, install with the UV-protected side facing the sun.
Can I cut Lexan myself?
Yes, polycarbonate can be cut with circular saws, jigsaws, or even score-and-snap methods for thin sheets. However, for precise, clean cuts without chipping, our custom cutting service delivers professional results with +/- 1/8" tolerance — and it's included with your order.
What thickness should I choose?
3mm (1/8") — Ideal for glazing, DIY projects, and applications where weight matters. Good for indoor use and light outdoor applications.
6mm (1/4") — Better for structural applications, machine guards, and areas requiring higher impact resistance. Recommended for larger panels and outdoor installations.
Ready to Order Custom Cut Polycarbonate?
Shop our selection of Lexan and Makrolon-grade sheets. Precision cut to your specifications with fast shipping across Canada.