Polycarbonate vs. Acrylic: Which Material Is Better for Windshields?

When it comes to windshields — whether for cars, motorcycles, boats, or even racing vehicles — the material you choose matters.
Safety, clarity, weight, and durability all play a role in performance. While glass is still the legal standard for road vehicles, polycarbonate and acrylic are popular alternatives in motorsports, custom projects, and off-road, machinery applications.
So, which is better for a windshield: polycarbonate or acrylic (plexiglass)? Let’s break it down.

Quick Comparison: Polycarbonate vs. Acrylic for Windshields

Features	Polycarbonate	Acrylic
Strength	~250x stronger than glass; highly impact-resistant	~10x stronger than glass; more brittle
Scratch Resistance	Requires coating; scratches more easily	Naturally more scratch-resistant
Weight	~50% lighter than glass	~50% lighter than glass
UV Resistance	UV coating to prevent yellowing	Naturally good UV resistance
Optical Clarity	High, but may distort if poorly formed	Very high, excellent clarity
Cost	Slightly more expensive	Cheaper option
Best Use Cases	Racing cars, aircraft canopies, off-road vehicles, motorcycles	Motorcycles, boats, budget projects

Durability and Safety

Polycarbonate is the clear winner in terms of impact resistance. It doesn’t shatter like glass or crack easily like acrylic. That’s why it’s used in bulletproof glass, fighter jet canopies, and racing windshields.
Acrylic, while strong compared to glass, is more brittle. A strong impact may cause it to crack or chip.

If safety is your priority (e.g., motorsports or off-road, like Honda), polycarbonate is the better choice.

Optical Clarity

Acrylic has superior optical clarity and less distortion, which is why it’s popular for motorcycle windshields and boat enclosures.
Polycarbonate offers good clarity too, but if improperly curved or formed, it may introduce slight visual distortion.

For everyday clarity, acrylic edges out polycarbonate — unless high-impact resistance is critical.

Scratch Resistance and Maintenance

Acrylic naturally resists scratches better, making it easier to maintain without special coatings.
Polycarbonate, on the other hand, is softer. It scratches easily if uncoated, but most polycarbonate windshields today come with hard-coat technology that dramatically improves scratch resistance. So, now we can say, polycarbonate windshield scratch resistance.

If you want long-term durability without worrying about scratches, acrylic is easier. With coating, polycarbonate performs just as well.

Design Flexibility: Thermoforming and Advanced Shapes

One of the biggest advantages of polycarbonate is its ability to be thermoformed into complex shapes. Unlike acrylic, which is more brittle and limited in forming, polycarbonate can be heated and molded into:

Curved windshields with extreme angles
Aerodynamic “wave” designs for racing and performance vehicles
Custom canopy-style enclosures for boats and aircraft

This makes polycarbonate the go-to choice for manufacturers and custom builders who need functional design plus safety.

UV Resistance and Weathering

Polycarbonate can yellow over time if not coated with UV protection.
Acrylic has excellent natural UV resistance and holds up well under the sun.

Cost Considerations

Acrylic is generally cheaper to produce and buy.
Polycarbonate costs a little more, but you’re paying for extra strength and impact resistance.

Applications

Polycarbonate: Race cars, military vehicles, aircraft canopies, bullet-resistant glass. NASCAR and Formula 1 cars use polycarbonate windshields because of its safety and shatterproof properties.
Acrylic: Motorcycle windshields, boats, display cases, budget off-road projects.
Thermoformed polycarbonate windshields are increasingly used in motorsports and specialty vehicles because they allow unique shapes without compromising safety.

Legal Considerations

In most countries, road vehicles legally require laminated glass windshields for driver safety. Polycarbonate and acrylic windshields are typically used in off-road, racing, or specialty vehicles only.

Recommendation

For maximum safety and durability → Go with polycarbonate (with hard-coat for scratch resistance).
For optical clarity and budget-friendly projects → Acrylic is a solid choice, especially for motorcycles and boats.
For street-legal vehicles → Stick to laminated glass unless laws allow alternatives.

FAQs

Q: Can you use acrylic for a car windshield?
Not legally in most places. Acrylic may work for off-road vehicles, but cars typically require laminated glass.
Q: Is polycarbonate street-legal for windshields?
Generally no, unless it’s for motorsports or specialty vehicles. Always check regulations.
Q: How do you clean a polycarbonate windshield?
Use a mild soap solution and microfiber cloth. Avoid ammonia-based cleaners, as they can damage the surface.
Q: Does polycarbonate yellow in the sun?
Yes, if uncoated. Most modern polycarbonate windshields include UV-resistant coatings.

Final Thoughts

If you’re working on a race car, off-road buggy, or custom motorcycle, the choice between polycarbonate and acrylic depends on your priorities.

Polycarbonate is the safer, stronger option, while acrylic is cheaper and clearer. For most performance applications, polycarbonate is the preferred choice.