Polycarbonate is a set of durable, impact-resistant thermoplastic resins that have relatively high heat resistance and color stability. It’s naturally clear and can transmit light almost as well as glass. It’s commercially known under trademarked names such as Makrolon or Lexan. It’s used for durable enclosures, windows for large and small applications, colored lenses for lighting applications, and a host of other projects. We sell polycarbonate in our store. It can also be found at hobby shops, art supply and craft stores, and plastic specialty stores.
Polycarbonate works very well with all sizes of end mills; however, the tool should be very sharp, preferably one reserved for use with plastics. Polycarbonate can melt under the end mill if too much heat builds up under certain conditions. For example, if the settings you’re using (speed, feed rate, depth of cut, etc.) cause the material you’re cutting to accumulate in the end mill flutes, the chips could melt the plastic to the tool, ruining your tool and workpiece.