Polycarbonate Protective Gear for Tactical Applications

Workers in high-risk professions, such as military and law enforcement, often rely on protective gear for their safety and wellbeing. These professions require individuals to carry out their duties in hazardous and sometimes hostile conditions, so reliable, long-lasting protection is critical to ensure smooth, safe operations. Naturally, protective gear is employed to mitigate, or at least minimize, the risks associated with these demanding jobs.

Protecting the face, especially the eyes, is especially important. In fact, U.S. Army medical records show that nearly 16% of all military personnel medical evacuations in Iraq involved eye injuries. In many cases, standard-issue protective eye gear fails to provide sufficient protection.

But appropriately designed polycarbonate shields can significantly reduce the likelihood of face and eye injuries by providing a superior protective barrier.

The Protective Properties of Polycarbonates

Polycarbonates are a group of thermoplastic polymers which offer unique strength, transparency, and optical characteristics. In fact, their aberration-resistant and transmittance properties are comparable to those of glass. Polycarbonates also have nearly eight times the impact strength of nylon. Featuring excellent heat-resistant properties, this unique material can even be combined with flame-retardant materials without significantly altering its optical properties.

Thanks to these unique characteristics, polycarbonates are used across a wide range of industries and applications. For example, the material’s optical and aberration-resistant properties make it ideal for the manufacture of protective eyewear, medical devices, security windows, automotive components, and lighting fixtures, while its flame-retardant and high-temperature capabilities make it well-suited for the manufacture of fire-resistant protective gear.

Polycarbonates are lightweight materials and, as a type of thermoplastic, can be molded as needed once liquefied. This makes polycarbonate well-suited for use in protective military and police shielding, as these products must be comfortable and lightweight while still offering optimal heat resistance and robustness. Polycarbonate’s UV-resistant properties, in particular, provide another benefit for the use of the material in eyewear protection applications.

And finally, polycarbonates are very pliable and can be modified by applying shock, similar to metals. While thermoforming is an easier method, the material’s high pliability permits it to be bent when small angles are needed. Offering great versatility and a range of unique properties, polycarbonates are ideal for the manufacture of all types of protective gear — such as riot shields, face shields, and capture shields, among others.

Polycarbonate Material Structure and Molding Capabilities

Polycarbonate contains a carbonate group in its chemical structure, imbuing the material with many useful properties, such as temperature resistance, impact resistance, and the optical properties described in the previous section.

Polycarbonates are typically molded into their desired forms. As a thermoplastic, polycarbonate melts at 155 °C, at which point it can be easily molded. Generally, plastic injection molding for polycarbonates takes place at about 135 °C, under a pressure of 264 psi. Adding glass fiber will increase the deflection temperature by about 4 °C.

A rapid heating and cooling method can also be employed, in which the mold surface is heated before injection, and then rapidly cooled. This technique can greatly improve final product quality, as this technique eliminates any surface imperfections that may interfere with the material’s optical properties. Weld lines can also be avoided. The polycarbonate product can then be further machined to ensure excellent dimensional stability.

Polycarbonate: Versatile, Protective, Reliable

Offering a range of unique optical, mechanical, and thermal properties, polycarbonates are well-suited to a range of different applications. Military, law enforcement, and other demanding professions employ polycarbonate in riot shields, face shields, and tactical gear. Any application whose requirements dictate the need for a strong, heat-resistant material with excellent optical clarity and aberration properties will benefit greatly from the use of this durable yet lightweight material.

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