The development of polycarbonate (PC) linear lighting profiles has revolutionized technical and industrial LED lighting systems. Thanks to advances in extrusion technology, today’s custom profiles offer superior light transmission, thermal resistance, mechanical durability, and design flexibility. These properties make PC profiles ideal for engineers and lighting manufacturers seeking optimal optical performance and long-term stability.
What is polycarbonate (PC) and why is it ideal for LED applications?
Polycarbonate (PC) is a high-performance engineering thermoplastic known for its impact resistance, heat stability, and excellent optical clarity. It’s widely used in sectors such as electronics, construction, automotive, and especially linear LED lighting systems.
Key characteristics of PC profiles for lighting:
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Impact resistance up to 250x higher than glass
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High optical clarity, up to 90% light transmittance
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Flame retardant grades: UL94 HB, V2, V1, V0
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Stable under thermal and chemical stress
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Compatible with extrusion, molding, thermoforming
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UV-resistant when properly treated
These properties make PC one of the most efficient materials for LED diffuser covers, combining visual performance with physical strength.
Light transmission in PC linear lighting covers
Thanks to custom formulations and the use of optical additives, polycarbonate linear LED profiles ensure high light diffusion with minimal loss. Both clear and opal variants maintain high transmittance, especially at reduced thicknesses.
Average light transmission by profile type:
| Thickness | Clear | Opal diffused |
|---|---|---|
| 2 mm | 88–92% | 55–60% |
| 4 mm | 83–88% | 48–53% |
| 10 mm | 70–75% | 35–40% |
Ideal applications:
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Linear LED diffuser profiles
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Translucent roofing and skylights
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Outdoor lighting covers
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Automotive light housings
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Natural daylight systems
Learn more: Polycarbonate vs Glass: Advantages and Disadvantages
Durability of polycarbonate lighting profiles
One of the key benefits of polycarbonate linear profiles is their long-term performance, even under demanding environmental conditions.
Long-term performance data:
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Excellent impact resistance in extreme temperatures
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UV resistance: >10 years with anti-yellowing treatment
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Flame rating: UL94 HB (V2, V1, V0 on request)
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Good chemical resistance (acids and oils; not suitable for esters/ketones)
Comparison with alternative materials:
| Material | Impact resistance | Transparency | Fire behavior | Workability |
|---|---|---|---|---|
| Polycarbonate (PC) | Excellent | Very high | Self-extinguishing (UL94 HB–V2–V1–V0) | Excellent |
| PMMA (Acrylic) | Low | Very high | Self-extinguishing (UL94 HB) | Excellent |
| Glass | Medium | Very high | Not self-extinguishing | Limited |
| Polystyrene (PS) | Low | High | Self-extinguishing (UL94 HB) | Good |
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Optical efficiency in LED systems: PC vs other materials
Polycarbonate LED profiles not only transmit more usable light but also enhance light diffusion, especially when co-extruded with custom optical additives.
Technical benefits:
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High transparency → lower energy loss, more effective lumens
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Uniform diffusion → reduces LED hot spots
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Thin walls → improved heat dissipation
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Dimensional stability → no deformation over time
| Material | Luminous efficiency* | Light diffusion** | Customization*** |
|---|---|---|---|
| Polycarbonate (PC) | ★★★★☆ | ★★★★★ | ★★★★★ |
| PMMA | ★★★★★ | ★★★☆☆ | ★★★★☆ |
| Glass | ★★★★★ | ★★☆☆☆ | ★★☆☆☆ |
| Polystyrene (PS) | ★★★☆☆ | ★★☆☆☆ | ★★★☆☆ |
* Theoretical value + long-term performance | ** Also extrudable with optical additives | *** Design flexibility during extrusion
The design freedom offered by polycarbonate allows the creation of frosted, prismatic, colored, or dual-color co-extruded profiles, tailored to any LED lighting concept.
Why choose polycarbonate (PC) linear lighting profiles for your next project?
Opting for PC linear LED profiles ensures:
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Custom shapes and finishes
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Long-lasting mechanical and optical performance
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Compliance with lighting safety and fire standards
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Lightweight, impact-resistant and UV-stable components
These advantages make polycarbonate extruded profiles the smart choice for technical lighting applications across multiple industries.
FAQ – Frequently asked questions about polycarbonate (PC) linear lighting profiles
How long do PC profiles last in outdoor LED systems?
With UV-resistant treatment, polycarbonate lighting profiles last over 10 years without significant yellowing or loss of mechanical strength.
Are PC profiles more durable than glass in lighting systems?
Yes, polycarbonate is up to 250 times more impact-resistant than glass and does not shatter, making it safer and more durable.
Can PC profiles be made with opal light diffusion?
Absolutely. Optical-grade additives can be used during extrusion to create homogeneous opal finishes that diffuse LED light effectively.
Request a consultation for your LED lighting project
Are you developing a linear LED system and need reliable, custom-engineered components?
Mavis Italy provides tailor-made extrusion solutions in polycarbonate and PMMA for high-efficiency LED lighting systems.
Fill out the form below or contact our technical team for a free consultation.
