Substitute for polycarbonate sheet?

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I need to make four dragon fly wings, each about 4 foot long by 10 inches wide or so. A 4 x 4 sheet of 1/4 inch polycarbonate sheet is $110.00 and I'm looking for a substitute. Must be clear, needs to be 1/4 thick or a thickness that gives some rigidity, and it needs to be workable by saw and sandpaper. Calling on the collective for ideas. Thanks!RonRonnie LyonsMeridian, Idaho
Reply:You might check around locally and see if you can't find a plastics shop that sells "drops". When I was in college a lot of the students in my classes flocked to two or three plastics companies who sold drops so they could use them in their models and save money. They'd also be the ones who might be able to recommend a less expensive alternative to polycarbonate..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:Acrylic (Plexiglas) is much cheaper than polycarbonate (Lexan).
Reply:I've seen sheets of Core-plast (corrugated plastic) in clear. It's not 100% transparent.....but it's light, about a 1/4" thick and pretty cheap. I know Home Depot used to sell it.....-Millermatic 211, Powermax 380, and way too many other tools to list....-Unofficial, professsional, garage tinkerer...
Reply:Originally Posted by ezduzitAcrylic (Plexiglas) is much cheaper than polycarbonate (Lexan).
Reply:Originally Posted by SuperArcPlexiglas is very difficult to cut (saw) cleanly...
Reply:Polycarbonate can be formed. acrylic will break, both cut the same to me, but acrylic can break while cutting if not supported..Tim Beeker.
Reply:Originally Posted by ezduzitNot so. If you use the right carbide blade it cuts cleanly on the table saw or (Festool) plunge saw. Same with polycarbonate. If you are having difficulty, try a sharp, fine-tooth blade made specifically for plastic. Although I have good luck with a triple chip blade. Scoring can assure chip-free edges on both sides, where necessary. Routing can produce a fine edge.
Reply:Originally Posted by tnjindPolycarbonate can be formed. acrylic will break, both cut the same to me, but acrylic can break while cutting if not supported..
Reply:Originally Posted by M J DLay the acrylic on 2 in. Styrofoam and cut with a sabresaw. Acrylic is formed with heat and vacumn all the time. If you have any inside corners drill with an 1-8 in. bit and sand your edges.
Reply:I would stay away from plexi glass, that stuff will brake and leave long sharp shards. Lexan can be worked, I had 1/4" lexan skid plates on my Kawasaki Teryx, I drilled, bent and thrashed on them with no regard to their well being and they held up fine. I made a plexi glass windshield and came out to the shop the next morning and it had broken right in half. Apparently it had shrunk when the heat was off and the stress was too much for it.
Reply:Not sure why you need 1/4" material and not knowing the installation I can only offer general help. I would think that if it must be made durable, .090" polycarbonate material would be more than sufficient, maybe even .060 would work. For the record, polycarbonate is softer and much stronger than Acrylic. Polycarbonate can be cold formed using a brake. Acrylics are harder is more "scratch resistant" but shatter easy. Acrylic bends easily with heat and both materials can easily be thermo formed. Scratches in Acrylic can easily be polished/buffed out, not so easy with polycarbonate.Here is another option for you if it is static display that will not be handled. I would bend up a wire frame (you can use welding rod) then shrink some model airplane Mylar film on it using a household iron and a hair dryer. You could make some pretty realistic looking wings with this method. One film name that comes to mind is MonoKote which comes in assorted colors. Check with a good model airplane store or online.MikeLast edited by mikee; 10-31-2013 at 02:02 AM.
Reply:You could use thin polycarb and add a few of the main ribs, just like a real dragonflt.This guy did a very good job.  He used stained glass!"USMCPOP" First-born son: KIA  Iraq 1/26/05Syncrowave 250 w/ Coolmate 3Dialarc 250, Idealarc 250SP-175 +Firepower TIG 160S (gave the TA 161 STL to the son)Lincwelder AC180C (1952)Victor & Smith O/A torchesMiller spot welder