🧩 PC-HI – High Impact Polycarbonate

(Modified version of standard polycarbonate, with superior mechanical strength and elasticity. Used in car parts exposed to shocks, vibrations, or large temperature fluctuations. Offers enhanced durability and crack resistance.)

🔹 What is PC-HI

PC-HI (High Impact Polycarbonate) is a modified version of classic polycarbonate (PC), obtained by adding elastomers or acrylic rubbers into the polycarbonate matrix.

This formulation significantly increases impact resistance, vibration absorption, and durability at low temperatures. The material maintains the clarity and rigidity of standard PC but offers greater flexibility and a higher tolerance for deformation, making it ideal for exterior parts, housings, and structural elements.

🔧 Composition

Polycarbonate (PC): 80–90 %
Elastomers (impact modifiers): 5–15 %
UV Additives / Stabilizers: 1–5 %
Density: 1.18–1.20 g/cm³
Softening Point: ≈ 140–150 °C
Melting Point: ≈ 230–250 °C
Chemical Resistance: Good (oils, detergents, mild solvents).
UV Resistance: Moderate (can be improved with ASA or PMMA coatings).

🚗 Where PC-HI is used in the automotive industry

Component	Example parts	Observations
Body Exterior	Sensor covers, mirror housings, grilles	High resistance to impact and vibration
Headlights & Signals	Lenses, light diffusers	Clarity + shock flexibility
Technical Interior	Module covers, fasteners, clips	Good absorption of mechanical stress
Safety Elements	Brackets, ADAS sensor housings	Stable behavior in cold and heat

🔧 Welding Temperature and Methods

Method	Optimal Temperature	Observations
Hot Air	280 – 320 °C	Careful control; material becomes malleable
Heat Plate (Mirror)	270 – 300 °C	Suitable for thick parts
Manual Extrusion	270 – 300 °C	Good for long cracks and strength welds

🔩 What to Weld PC-HI With (Material Compatibility)

Being polycarbonate-based, PC-HI behaves similarly to standard PC but allows for a more tolerant weld due to its flexibility.

✅ Compatible with:

PC-HI ↔ PC / PC+ABS / PC+ASA / PC+HI – very good bond.
PC-HI ↔ ABS / ABS+PC / ASA+PC / SAN+ABS – partially compatible.

❌ Incompatible with:

PP, PE, PA, PVC, PS, TPO – large differences in melting and shrinkage.

💡 ReplastMD Recommendation:

Use PC+ABS rods or PC-HI rods at 290–310 °C. Maintain a constant temperature to avoid “bubbles” in the weld zone. After welding, a UV protective layer or polish can be applied for the finish.

🏭 Manufacturers and Trade Names

Covestro: Makrolon® HI
SABIC: Lexan® HPI / Lexan® XHR
Trinseo: CALIBRE™ Impact
LG Chem: LUPOY® HI

🧠 How to Identify PC-HI

Engraved marking: >PC-HI<, >HI-PC<, >Lexan XHR<.
Semi-transparent material, slightly flexible.
Softens earlier than standard PC (≈ 150 °C).
Yellow-blue flame, faint odor.
After cooling, it retains its gloss and does not crack under pressure.

🛠️ PC-HI Welding at ReplastMD:

At ReplastMD (Chisinau, Ciocana sector), we perform professional PC-HI welding for headlight housings and shock-resistant caps, providing a flexible, durable, and “like-new” finish.