Polycarbonate vs. Polysulfone — What's the Difference?

Polycarbonate (PC) is widely recognized for its impressive combination of optical clarity and mechanical strength, making it an ideal choice for products requiring transparency and durability, such as bullet-proof glass and various consumer goods. On the other hand, polysulfone (PSU) distinguishes itself with superior thermal stability and chemical resistance, which makes it suitable for high-temperature applications and environments where exposure to harsh chemicals is common, like in certain medical devices and food processing machinery.

One of the key advantages of polycarbonate is its exceptional impact resistance. It can absorb significant energy without breaking, which is why it's used in safety goggles, helmets, and vehicle parts. Polysulfone, while also durable, excels more due to its ability to withstand continuous exposure to high temperatures and aggressive cleaning agents without degrading, a property valued in the healthcare and aerospace industries.

When it comes to processing and molding, polycarbonate is relatively easy to work with, allowing for the production of complex shapes and fine details, which is advantageous in the manufacturing of consumer electronics and compact discs. Polysulfone, however, requires more stringent processing conditions due to its higher melting point, limiting its use to specialized applications where its unique properties are needed.

In terms of environmental resistance, polycarbonate offers good resistance to weathering, making it suitable for outdoor applications. It does, however, have a tendency to yellow over time when exposed to UV light, a limitation that can be mitigated with the addition of UV stabilizers. Polysulfone is inherently more resistant to UV radiation and does not require additional stabilizers to maintain its physical properties and appearance over time.

Both materials are regarded for their electrical insulating properties, but polysulfone's higher thermal resistance makes it a preferred material for electrical connectors and components that must operate in elevated temperatures or fluctuating thermal conditions. Polycarbonate, while also used in electrical applications, is more commonly selected for its balance of electrical insulation and impact resistance in consumer-level products.