Custom Cut Lexan (Polycarbonate) — Ordering Sheet to Your Size
Lexan is a brand name for polycarbonate sheet — the same material, the way Plexiglas means acrylic (more on that in Lexan vs. Polycarbonate). So when a job calls for custom cut Lexan, what you order is polycarbonate cut to size. We stock standard-grade virgin clear polycarbonate and cut every piece to your exact dimensions, with the price shown instantly — no quote for straight cuts, no minimum order.
The thicknesses we stock
Seven thicknesses of clear polycarbonate, thinnest to thickest. Each links to its own page with pricing and typical uses:
- 1/16" polycarbonate
- 3/32" polycarbonate
- 1/8" polycarbonate
- 3/16" polycarbonate
- 1/4" polycarbonate
- 3/8" polycarbonate
- 1/2" polycarbonate
As a quick rule: thin sheet (1/16″–3/32″) is for framed glazing, facings, and covers that flex; 1/8″ is the workhorse — the thickness most people mean when they say Lexan — for machine guarding, safety glazing, and equipment windows; 3/16″ spans further without bowing; and 1/4″ through 1/2″ is the thick end, chosen for security glazing, heavy guarding, and impact shields where the panel itself is the protection.
How ordering works
On the polycarbonate page, pick a thickness, then either choose a standard size or enter your own width and height. The price updates as you type, and you check out directly. Pieces are parcel-shipped nationwide, so dimensions stay within parcel limits — up to 48″ on the longest side. Oversized pieces are quote-only: send us the size and thickness and we'll tell you straight whether we can do it.
One thing we do differently from acrylic: polycarbonate is saw-cut, never laser cut. In a laser it scorches brown, cuts badly, and can catch fire — whatever brand name is on the masking. Saw-cutting gives a clean, accurate edge; unlike acrylic, polycarbonate can't be flame-polished to a glass-like finish, so if a show-polished edge matters more than impact resistance, acrylic may be the better material.
Looking for black or smoked Lexan?
We stock clear today. The two most-asked-for tints have their own pages while we bring them in: black polycarbonate for guards and covers that shouldn't be seen through, and smoked polycarbonate where you want to cut glare but still see what's behind it. Black acrylic is in stock now if the piece won't take impacts.