--- title: "Acrylic vs Polycarbonate vs PETG — A B2B Material Showdown for Custom Clear Boxes" description: "Acrylic plastic box vs polycarbonate vs PETG — clarity, drop test, UV yellowing, $/kg cost, and recyclability scored side by side from our test rig." category: "Comparison" author: "Dillion Chen" authorCredential: "Production Manager at Wetop Acrylic — running laser, CNC, polishing, and UV printing lines since 2014, 1,500+ custom projects personally overseen" datePublished: 2026-05-05 dateModified: 2026-05-05 primaryKeyword: "acrylic plastic box" url: https://wetopacrylic.com/guide/acrylic-plastic-box-vs-polycarbonate-vs-petg/ --- ## Acrylic vs Polycarbonate vs PETG: The 30-Second Answer {#short-answer} For a custom B2B clear box, pick cast **acrylic plastic box** construction when clarity, edge finish, and UV stability drive the spec — display boxes, retail fixtures, signage enclosures, premium presentation cases. Pick polycarbonate when the box gets dropped, hit, or pressed against — tool cases, shipping enclosures, machine-side covers, vandal-resistant signage. Pick PETG when the design is thermoformed, the wall is under 3mm, and budget matters more than premium finish — clamshell packaging, light-duty point-of-sale boxes, low-cost protective covers. In 12+ years running Wetop's production floor, I've quoted thousands of clear-box jobs across all three materials. The mistake I see most often is buyers spec'ing polycarbonate because they read it's "stronger" and stopping there — then receiving boxes with an amber tint that yellows visibly within two years, paying 30–40% more, and finding their fabricator can't deliver clean laser-cut edges anyway. The opposite mistake is spec'ing cast acrylic for a box tossed into warehouse bins daily, then dealing with replacement orders every 90 days when corners crack. This guide walks through our test-rig data — drop, scratch, UV, and cost — and tells you which material wins each round. --- ## How the Three Materials Score Across Six Dimensions {#scorecard} Before diving into each test, here's the headline scorecard from our internal rig and material-cost benchmarks. We score on a 1–5 scale per dimension where 5 is best in class. The same boxes (250×150×150mm, 6mm wall on acrylic and PC, 4mm on PETG to match thermoforming reality) ran through every test. ### Material comparison scorecard — acrylic vs polycarbonate vs PETG | Dimension | Cast Acrylic | Polycarbonate | PETG | Winner | |---|---|---|---|---| | Optical clarity (light transmission, edge clarity) | 5/5 (92%, crystal edge) | 3/5 (88%, amber tint) | 4/5 (90%, faint blue) | Acrylic | | Impact strength (4ft drop, 4-corner test) | 2/5 (5 of 12 survived) | 5/5 (12 of 12 survived) | 4/5 (11 of 12 survived) | Polycarbonate | | Scratch resistance (Mohs hardness) | 4/5 (Mohs 3) | 3/5 (Mohs 2.5) | 2/5 (Mohs 2) | Acrylic | | UV stability (12-month outdoor ΔE) | 5/5 (ΔE 1.2) | 2/5 (ΔE 6.1 untreated) | 3/5 (ΔE 3.8) | Acrylic | | Cost (per finished box, B2B 50-piece MOQ) | 4/5 ($18–$32) | 2/5 ($26–$45) | 5/5 ($11–$18) | PETG | | Recyclability (2026 municipal access) | 2/5 (resin 7, specialty) | 1/5 (resin 7, rare) | 5/5 (resin 1, curbside) | PETG | The verdict per material: cast acrylic wins on clarity, scratch, UV, and overall finish quality — the right default for any visible-edge custom **acrylic plastic box**. Polycarbonate wins on impact alone but pays for it in clarity, UV stability, and cost. PETG splits the difference and dominates only on cost and recyclability, making it the right call when the box is disposable or single-use.
Material comparison scorecard showing acrylic, polycarbonate, and PETG ranked across optical clarity, impact strength, scratch resistance, UV stability, cost, and recyclability with star scores per cell
Six dimensions, three materials, one scorecard. Acrylic wins four of six categories — but polycarbonate's impact win is sometimes decisive.
--- ## Optical Clarity — Where Acrylic Genuinely Pulls Ahead {#clarity} The clarity gap between the three materials is the most visually obvious property when you put them side by side, and it's the one buyers underweight most often when they spec a custom clear box. Cast acrylic transmits roughly 92% of visible light per ASTM D1003 testing, with no detectable tint at any thickness our customers typically order (3–20mm). PETG transmits about 90% with a faint blue tint that becomes visible on walls thicker than 5mm and along thicker laser-routed edges. Polycarbonate transmits around 88% with a noticeable amber tint that deepens with thickness and gets worse over time as UV exposure accumulates. For a side-by-side **acrylic plastic box** versus polycarbonate box on a retail shelf, the clarity difference is the first thing a customer notices — even if they can't articulate why. The amber tint on polycarbonate reads as "older" or "lower quality" instinctively, even when the polycarbonate box is brand new and identical in every other dimension. PETG sits in the middle: cleaner than polycarbonate, slightly less crisp than acrylic, and acceptable for most secondary display applications where the box isn't the hero. Edge clarity is the second axis where the materials separate. Cast acrylic, when laser-cut, produces a flame-polished glass-like edge straight off our CO2 laser line — no secondary polishing required, and the optical clarity at the edge matches the face. Polycarbonate cannot be laser-cut cleanly; the material chars and melts, releasing chlorine-like fumes that damage equipment, so we route it on CNC and finish each edge mechanically through 4–6 grit progressions. The mechanically polished PC edge is acceptable but never matches a laser-cut acrylic edge. PETG sits in between — also CNC-routed, also mechanically finished, with marginally cleaner edges than polycarbonate but still well below cast acrylic's laser finish. For any project where the box is the display vehicle — premium retail packaging, presentation cases, signage enclosures, [automotive showroom countertop displays](/case-studies/automotive-showroom-countertop-displays/) — acrylic wins on clarity alone. For the deeper two-way comparison, see our [polycarbonate vs acrylic guide](/guide/polycarbonate-vs-acrylic/). --- ## Impact Strength — Drop Test Data Across Three Materials {#impact} Impact is the only dimension where polycarbonate clearly beats both acrylic and PETG, and it's the dimension that flips the recommendation when the application demands it. We ran a standardized drop test on our internal rig: identical boxes (250×150×150mm), three materials, three thicknesses (3mm, 4.5mm, 6mm), four corner drops per box from a 4-foot height onto a polished concrete floor. The boxes were dropped corner-first because corners are the highest-stress geometry on any rectangular enclosure — face drops are far more forgiving and don't separate the materials clearly. The 6mm results, where the data is cleanest: - **Polycarbonate (6mm):** 12 of 12 corners survived without cracking. Two corners showed minor surface scuffing; none compromised structural integrity. - **PETG (6mm):** 11 of 12 corners survived. One corner developed a hairline crack on the third drop and propagated on the fourth. - **Cast acrylic (6mm):** 5 of 12 corners survived. Six corners cracked on the first or second drop; one box shattered cleanly on the first impact. At 4.5mm and 3mm the gap widened: acrylic's drop survival fell below 30% at 3mm, while polycarbonate stayed above 90% all the way down. PETG held steady around 80% across all thicknesses. The Izod notched-impact data behind these results, per ASTM D256[^astm-d256]: cast acrylic measures roughly 0.4 ft-lbs/inch of notch, PETG measures 1.7–2.1 ft-lbs/inch, and polycarbonate measures 12–18 ft-lbs/inch — roughly 30–45 times acrylic. ASTM D790 flexural data[^astm-d790] tells a similar story: polycarbonate flexes past its yield point before fracture while acrylic snaps clean. The practical takeaway: if your box gets dropped, stacked aggressively, or shipped without protective packaging, spec polycarbonate. If it sits on a counter or behind a window, acrylic's impact strength is more than the application demands. For the in-between case where some shatter resistance matters but clarity still drives the spec, PETG is the third option worth pricing. --- ## UV + Yellowing — 12-Month Outdoor Exposure Data {#uv} UV resistance separates acrylic from polycarbonate even more sharply than impact resistance does, but in the opposite direction. We ran a 12-month outdoor UV exposure test on our factory roof in Dongguan (sub-tropical climate, high UV index averaging 9–11 most months) using identical box panels mounted at 30° tilt facing south, with monthly ΔE readings using a spectrophotometer. The 12-month results: - **Cast acrylic (no UV stabilizer):** ΔE 1.2 — essentially invisible to the naked eye, within typical batch-to-batch variance. - **PETG:** ΔE 3.8 — a faint amber haze visible on close inspection, more noticeable when compared to a fresh sheet side by side. - **Polycarbonate (no UV stabilizer):** ΔE 6.1 — clearly yellowed and slightly brittle at the surface, with visible chalking starting around month 9. - **UV-stabilized polycarbonate (Makrolon UV-grade equivalent):** ΔE 2.5 — visibly better than untreated PC but still noticeably worse than untreated acrylic, at a 15–25% material cost premium. The UV gap matters most for outdoor signage boxes, storefront display enclosures, and any box sitting within 3 meters of a south-facing window. Untreated polycarbonate will look noticeably worse within 18 months and need replacement before the typical refresh cycle. Untreated cast acrylic holds its appearance for 8–10 years in the same conditions. The chemistry behind the gap: polycarbonate's carbonate linkages absorb UV at 300–340nm, breaking polymer chains at the surface and generating yellow degradation products. Acrylic's methyl methacrylate backbone is largely transparent at those wavelengths, so the surface stays clear. PETG sits in between — more UV-resistant than PC, less so than acrylic. --- ## Cost — $/kg Material vs $/Part Finished {#cost} Material cost per kg only tells part of the cost story for any custom **acrylic plastic box** — fabrication labor and finishing time often matter more for the finished unit price. Here's the breakdown across both axes, using indicative US distributor pricing as of June 2025 (your local market may vary 15–25%). ### Raw material cost per kg (June 2025, US distributor) - **PETG sheet:** ~$2.80/kg ($1.27/lb). Cheapest of the three. - **Cast acrylic sheet:** ~$4.20/kg ($1.91/lb). Roughly 50% more than PETG. - **Polycarbonate sheet:** ~$5.50/kg ($2.50/lb). Roughly twice PETG and 30% more than cast acrylic. - **UV-stabilized polycarbonate:** ~$6.50/kg ($2.95/lb). Roughly 15–25% premium over standard PC. ### Finished box cost per unit (50-piece MOQ, 250×150×150mm, B2B custom) - **PETG (3mm thermoformed):** $11–$18 per box. Cheapest finished cost. Limited finishes, no laser-cut edges. - **Cast acrylic (5–6mm laser-cut + solvent-bonded):** $18–$32 per box. Premium finish, fastest fabrication, widest finish options. - **Polycarbonate (6mm CNC-routed + adhesive-bonded):** $26–$45 per box. Highest finished cost, longest lead time, most complex polishing. The cost rank flips between raw material and finished part because fabrication labor compounds the differences. Cast acrylic laser-cuts in minutes with a finished edge straight off the machine; polycarbonate takes 3–5 times longer on CNC plus mechanical polishing. PETG thermoforms cleanly for simple shapes, which is why it dominates on cost when the design is thermoformable, but becomes uncompetitive against acrylic when the design needs flat panels with bonded corners — which describes most premium display boxes. Scrap rate is the cost factor most buyers miss. Cast acrylic and PETG run cleanly on our lines at 3–5% scrap. Polycarbonate's moisture sensitivity during thermoforming and its tendency to scratch on handling push scrap to 8–12% on complex shapes — and that waste flows directly into the finished part price. For an exact quote on your specific box dimensions, wall thickness, finish, and quantity, send specs to inquiry@wetopacrylic.com — we'll quote all three materials when the application genuinely calls for comparison and tell you directly which we recommend for your use case. We respond within 24 hours. --- ## Recyclability — What Each Material Can Claim in 2026 {#recyclability} Sustainability claims have become a real RFQ requirement in 2026, especially for B2B buyers selling into European and California markets where extended producer responsibility (EPR) regulations are tightening. Here's what each material can honestly claim under 2026 municipal recycling realities, referenced against the SPI Resin Identification Codes[^spi]. **PETG (resin code 1, sometimes 7 by region):** the most municipally recyclable of the three. PETG is chemically compatible with the PET stream that handles beverage bottles, though some facilities sort it as "other" due to the glycol modifier. In practice, PETG packaging is accepted by 30–50% of US curbside programs and higher in EU EPR markets. **Cast acrylic (resin code 7, "other"):** technically recyclable but rarely accepted curbside. Specialty channels exist — chemical depolymerization back to MMA monomer, mechanical regrinding for non-clear use — but municipal programs almost never accept it. The honest claim is "recyclable through specialty channels." We can take back our own production scrap for regrind into colored acrylic, which is an option some buyers like for closed-loop programs. **Polycarbonate (resin code 7, "other"):** the hardest to recycle. PC's complex polymer structure makes mechanical recycling impractical, and chemical pathways exist at industrial scale but are not municipally accessible. PC boxes end up in landfill or incineration in most markets. Practical guidance for 2026 RFQs: if recycle-claim is a hard requirement, default to PETG for disposable boxes and cast acrylic with a closed-loop takeback for premium display boxes. Polycarbonate is the right call only when impact, heat, or security override the sustainability cost. --- ## Which Material to Spec for Your Box {#decision} For the vast majority of custom B2B clear-box projects, the right answer is cast acrylic — specifically a laser-cut, solvent-bonded **acrylic plastic box** at 4–6mm wall thickness depending on the application. The decision tree below covers the cases where polycarbonate or PETG is the correct call instead. **Spec cast acrylic if:** the box is a display vehicle where clarity drives buyer perception (retail display, signage enclosure, premium presentation case, point-of-sale fixture), OR the box sits outdoors or near a window where UV stability matters, OR the design needs invisible solvent-bonded corners, OR the design includes laser-cut details, custom shapes, or polished edges, OR the buyer values long-term color stability over impact survival. **Spec polycarbonate if:** the box gets dropped, handled aggressively, stacked without packaging, or used as a tool case or shipping enclosure, OR ballistic / vandal resistance is part of the spec, OR the box sits within 30cm of a heat source above 95°C, OR the design tolerates the amber tint and faster yellowing in exchange for impact survival. **Spec PETG if:** the design is thermoformed (clamshell, vacuum-formed enclosure, compound curve), OR the wall thickness is under 3mm where acrylic gets fragile, OR the buyer needs a curbside-recyclable claim, OR budget pressure dominates and the box is single-use or short-lifecycle, OR the application falls between acrylic and polycarbonate on impact requirements. For premium custom display boxes, presentation cases, and retail fixtures, we fabricate primarily in cast acrylic — see our [acrylic display cases hub](/products/acrylic-cases/) for the full product range and configuration options. If your design brief specifies polycarbonate or PETG and you'd like a second opinion on whether cast acrylic is viable, include that question when you send your RFQ. I review every quote personally and will give you a direct answer — if polycarbonate or PETG is genuinely the right material for your application, I'll confirm that and we'll source it; if cast acrylic will meet the requirement at lower cost or better finish, I'll tell you that too. For related material decisions, our [polycarbonate vs acrylic guide](/guide/polycarbonate-vs-acrylic/) goes deeper on the two-way comparison without PETG, and our [custom acrylic RFQ guide](/guide/acrylic-rfq-guide/) walks through every spec you should include upfront to get accurate quotes the first time. To start your quote now, [send your specs through our contact form](/contact?source=plastic-box-materials) and we'll respond within 24 hours. ## Related guides - [Acrylic Sneeze Guard Specs 2026 — Healthcare & Restaurant Buyer Guide](/guide/acrylic-sneeze-guard-specs-healthcare-restaurant/) - [Etched Logo on Acrylic Trays — A Brand Buyer's Spec Sheet](/guide/etched-logo-acrylic-trays-spec/) [^astm-d256]: [ASTM D256 — Standard Test Methods for Determining the Izod Pendulum Impact Resistance of Plastics](https://www.astm.org/d0256-10r18.html) — referenced for the notched-impact figures comparing acrylic, polycarbonate, and PETG. [^astm-d790]: [ASTM D790 — Standard Test Methods for Flexural Properties of Unreinforced and Reinforced Plastics](https://www.astm.org/d0790-17.html) — referenced for the flexural-strength and bend-before-break behavior comparison across the three materials. [^spi]: [SPI Resin Identification Codes (ASTM D7611)](https://www.astm.org/d7611_d7611m-21.html) — the standardized resin coding system used to determine 2026 municipal recyclability for PETG (code 1), cast acrylic (code 7), and polycarbonate (code 7).