I'm looking for advice on how to bond two large sheets of polycarbonate and acrylic into a clear sandwich. I tried using transparent UV glue, but I ran into some issues: I couldn't eliminate all the air bubbles, and the joint remains cloudy. I suspect this is because I didn't apply enough pressure and trapped air underneath, but even the areas without bubbles look unclear. Has anyone successfully tackled this type of project and found a reliable solution?
5 Answers
Acrylic expands more with heat than polycarbonate does. They might stay bonded for a while, but as temperatures change, you could see them start to split apart, which won't be pretty. You mentioned glass wasn't an option, but have you considered tempered or laminated glass? They could end up being roughly the same cost, especially for smaller pieces.
The size of your sheets and your clamping method really matters here. Getting all the bubbles out is tough without a vacuum chamber. Even then, make sure you're applying uniform pressure across the whole surface; otherwise, you might end up with uneven thickness. Consider using a thicker transparent plastic layer and laminating a thin film instead, it might be a more effective approach than trying to achieve a perfect bond with adhesive.
Make sure the glue you use is compatible with polycarbonate to avoid crazing. It can lead to unexpected damage to your pieces.
What exactly are you trying to create with this bond?
Do you really need them bonded fully? You could just attach them at the edges and cover that part with some trim to keep it looking neat.
A vacuum bag clamp could help. Just remember, you might need a stronger vacuum than what a regular shop vac provides!