Bullet resistant polycarbonate is a strong, versatile, and relatively light weight protective glazing material with a wide array of applications in secured indoor and outdoor environments. While no material is truly “bullet proof” and able to withstand a nonstop barrage of bullets, bullet resistant polycarbonate does provide reliable resistance against specific ballistic threats.
Since there are a handful of different bullet resistant materials available, it’s important that you understand what each one brings to the table. Here’s a quick explanation of some of the pros, cons, and other characteristics of bullet resistant polycarbonate to help you determine whether this glazing material is the right choice for your building project.
About Bullet Resistant Polycarbonate
Polycarbonate is a synthetic material that is made up of thermoplastic polymers that contain carbonate structures within their chemical makeup. Essentially, it is a plastic that is particularly strong and durable.
When used in bullet resistant systems, multiple layers of polycarbonate are laminated together using a polyurethane interlayer protective glazing material. This is designed to make the material even stronger and more durable.
Pros of Bullet Resistant Polycarbonate
Bullet resistant polycarbonate is one of the thinnest ballistic protection options available. Laminated polycarbonate systems can meet UL level 1 bullet resistance at just ¾”. This means that it is fairly light and easy to fabricate, cut, shape, notch, drill, and fasten into place. Those characteristics allow it to be produced and installed efficiently, making it a simple and relatively affordable option.
Beneficial Softness
In addition to being strong and lightweight, polycarbonate is also fairly soft compared to other bullet resistant materials.
Because of that softness, it can actually catch a bullet within the sheet. The material will not shatter into dangerous shards, and the bullet will not ricochet around the room and potentially cause further damage or injury.
Cons of Bullet Resistant Polycarbonate
Despite its impressive strength and versatility, polycarbonate bullet resistant glazing may not be the right solution for every building project. Polycarbonate material does have a slight tint to it. Since bullet resistant polycarbonate is made out of multiple layers, it does not offer water-like clarity like glass and acrylic.
Although it is a very strong form of plastic and has a mar-resistant coating over the exterior, polycarbonate isn’t quite as durable as actual glass. It can scratch or show other signs of wear over time. It is also only at its most effective when used in systems that meet the standards of UL levels 1-3, and not available in higher levels of ballistic protection.
This is why builders sometimes opt for other glazing options, such as glass-clad polycarbonate materials, for certain projects.
If you’re looking to learn more about bullet resistant polycarbonate, or if you want to invest in this type of system for your building, contact Insulgard today. We offer a variety of polycarbonate protective materials, along with other options like acrylic, laminated glass, and glass-clad polycarbonate. Our team can help you better understand which materials are best suited to your particular needs and create a custom system that will provide the exact level of protection you need.
Bullet-Resistant Polycarbonate vs. Glass-Clad Polycarbonate: A Quick Comparison
Both materials provide crucial ballistic protection, but key differences in composition, performance, and use cases set them apart.
Bullet-Resistant Polycarbonate
✔ Lightweight & Flexible – Easier to handle and install, making it ideal for applications where weight is a concern (e.g., security windows, vehicle armor).
✔ Impact-Resistant – Absorbs energy effectively, reducing spalling upon impact.
✖ Prone to Scratches – Requires additional coatings for abrasion resistance.
Best For: Interior applications requiring lighter ballistic protection, such as retail stores or low-risk commercial spaces.
Bullet-Resistant Glass-Clad Polycarbonate
✔ Superior Durability – Outer glass layers resist scratches, wear, and weathering better than standard polycarbonate.
✔ Higher Ballistic Resistance – More effective against sustained or higher-powered ballistic threats.
✖ Heavier & Contains Glass – Less versatile and more challenging to fabricate and install.
Best For: Exterior applications or high-security environments like military bases, government buildings, and transactional areas where optical clarity is crucial.
Choosing the Right Material
- For lightweight and flexible security: Polycarbonate is likely the best choice.
- For long-term durability and higher security needs: Glass-clad polycarbonate is preferred.
Bullet Resistant Polycarbonate’s Many Applications
Bullet-resistant polycarbonate is a top choice for security and safety due to its lightweight nature and high-impact resistance.
Where It’s Used:
- Financial Institutions & Retail Stores – Secure transaction windows and entryways protect against ballistic threats.
- Commercial & Residential Security – Reinforces storefronts, doors, and reception areas against forced entry and gunfire while resisting shattering.
- Critical Infrastructure – Airports, embassies, and data centers rely on polycarbonate enclosures and partitions for high-security protection.
- Schools & Public Buildings – Integrated into windows and doors to improve safety in active threat situations.
Polycarbonate’s versatility, durability, and lightweight design make it a preferred material for ballistic protection across multiple sectors.
Insulgard’s UL-Rated Laminate Polycarbonate Products
- RATING: UL 752 Level 1
- MATERIAL: Lexgard Laminate
- NOMINAL THICKNESS: 0.750 In
- WEIGHT: 4.6 lbs/sq ft
- RATING: H.P. White HPW-TP-0500.02 Forced Entry Level 4; UL 752 Level 2; ASTM F1233 Class 5; Blast GSA; UFC
- MATERIAL: Lexgard® Laminated Polycarbonate
- NOMINAL THICKNESS: 1.030 In
- WEIGHT: 6.4 lbs/sq ft
- RATING: UL 752 Level 3; H.P. White HPW-TP-0500.02 Forced Entry Level 5; ASTM F1233 Class 5; ASTM F1915 Grade 1
- MATERIAL: Lexgard Laminate
- NOMINAL THICKNESS: 1.240 In
- WEIGHT: 7.7 lbs/sq ft
- RATING: UL 752 Level 2
- MATERIAL: Lexgard Laminate
- NOMINAL THICKNESS: 0.86 In
- WEIGHT: 6.4 lbs/sq ft
- RATING: UL 752 Level 6
- MATERIAL: Lexgard Laminate
- NOMINAL THICKNESS: 1.250 In
- WEIGHT: 7.7 lbs/sq ft
Look at our full line of bullet resistant glazing materials to select the products that are right for your project.
Build With Confidence
Insulgard designs and manufactures bullet resistant glass and other architectural security products trusted by architects, glazing contractors, and other construction professionals across the U.S. All of our bullet resistant materials meet the rigorous testing standards of the Underwriters Laboratories (UL), a global safety certification organization that tests and certifies products to meet stringent safety standards.
When you are ready to select the Insulgard security products that are right for your project, our experts will be here to provide guidance and support. Contact us or request a quote today.
