Top 15: Complete Guide to Wholesale High Quality Polycarbonate Overlays

Polycarbonate overlays are a cornerstone material in modern manufacturing — offering exceptional durability, clarity, and resistance to wear and tear. From secure ID cards to architectural panels and in-mold electronics (IME), polycarbonate films and overlays play a vital role in protecting, decorating, and extending the life of products.

What is a Polycarbonate Overlay?

Composition and Basic Properties

Polycarbonate (PC) is an amorphous engineering thermoplastic known for:

• High impact resistance — up to 250 times stronger than glass.

• Optical clarity — excellent light transmission for protective covers and displays.

• Heat tolerance — continuous service temperatures up to ~140°C.

• Dimensional stability — resists warping under heat and pressure.

Polycarbonate overlays are thin sheets or films of PC used as surface protection layers or as integral layers in laminated products, especially in secure ID cards and industrial graphics.

Common Formats and Constructions

• Monolithic films: Single-layer clear or tinted films.

• Coated overlays: Hard-coated or anti-glare surfaces for scratch/UV resistance.

• Metallized films: PC films with a decorative or functional metal layer.

• Security-grade overlays: Multi-layer films with embedded features like holograms.

Types of Polycarbonate Overlays

1. Clear Protective Overlays

These transparent films protect printed surfaces from scratches, UV damage, and chemical exposure. Common in:

• ID cards

• Signage

• Electronic displays

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2. Security & ID Card Overlays

Used in multi-layer card construction:

• Laser-markable surfaces

• Tamper-evident features

• Fusion-bonded to card cores for permanence

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3. Specialty Overlays (Polycarbonate Paper)

Polycarbonate “paper” is a flexible, printable PC film used in specialty security documents and niche industrial uses.

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Key Applications

Secure ID Cards & Passports

Polycarbonate overlays form the outer protective layer in many government-issued IDs and passports.

Benefits:

• High tamper resistance when fusion-laminated.

• Laser engraving compatibility.

• Long service life (10+ years without peeling).

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Performance & Quality Control

Impact Resistance

Polycarbonate overlays outperform PVC and PETG in impact resistance — crucial for protective covers and security documents.

Thermal Stability

Maintains shape and clarity in high-heat environments (automotive, outdoor).

Abrasion Testing

Hard-coated PC films can withstand thousands of Taber abrasion cycles without visible wear.

Security Testing

For ID applications:

• Tamper attempts should show visible damage.

• Fusion bonds should resist delamination.

Design & Specification Guide

Thickness Selection

• 30–250 μm for overlays

Surface Finish

• Gloss for clarity

• Matte/anti-glare for displays and outdoor readability.

Print Compatibility

• Screen printing, offset, and digital printing possible with correct ink systems.

• For IME: ensure compatibility with conductive inks.

Advantages & Comparisons

Polycarbonate vs PVC

• Pros: Higher impact resistance, better heat stability, more secure lamination.

• Cons: Higher cost, requires higher processing temperatures.

Polycarbonate vs PETG

• Pros: Stronger, more heat-resistant.

• Cons: Less formable, slightly harder to process.

Conclusion & Call to Action

Polycarbonate overlays are a versatile solution for industries that demand durability, security, and clarity. Whether you need protective films for ID cards, metallized finishes for electronics, or specialty PC laminates for signage, polycarbonate offers a combination of strength, processability, and longevity unmatched by most plastics.

Looking for a reliable supplier?

At Shanghai Wallis Technology Co., Ltd., we specialize in high-quality polycarbonate overlays, PC lamination films, and custom-coated PC products.

Contact us today to request free samples, technical datasheets, or a custom quote tailored to your application.