Polycarbonate Extrusion

As a premier polycarbonate extrusion manufacturer, Keller Plastics as a plastic extrusion company we specialize in transforming complex designs into tangible, high-quality products. Our advanced manufacturing processes and deep understanding of material science set us apart, ensuring that every client receives products that not only meet but exceed their expectations. Our focus on sustainable practices and quality control makes us the preferred partner for businesses seeking reliable and effective extrusion services.

Custom Polycarbonate Extrusions for Unique Needs

At Keller Plastics, we excel in crafting custom polycarbonate extrusions that meet a broad spectrum of unique industrial and commercial requirements. As trusted polycarbonate extrusion manufacturers, our products deliver exceptional mechanical strength, clarity, and durability. 

  • High Temperature and Impact Resistance: Ideal for applications in automotive and aerospace industries, our polycarbonate extrusions withstand extreme temperatures and impacts, making them perfect for components like headlight lenses and aircraft windows.
  • Electrical Insulation: For the electronics industry, where safety and performance are paramount, our polycarbonate profiles provide excellent electrical insulation properties, which are essential for enclosures and insulating barriers.
  • Chemical and Stain Resistance: In chemical processing and healthcare sectors, our materials offer resistance to a wide range of chemicals, as well as stains from common agents like coffee, tea, and cosmetics, ensuring durability and ease of maintenance.
  • Custom Aesthetics: Whether the requirement is for high-gloss finishes that mimic glass and metal or specialized colors and textures, we provide custom aesthetic options that enhance the product’s appeal without sacrificing functionality.

Through our advanced extrusion techniques, Keller Plastics meets these diverse needs with precision, ensuring each product is optimized for its specific environment. Our commitment to innovation allows us to not only follow industry trends but also set new standards in polycarbonate extrusion.

Integrating Advanced Materials: Nylon, PEEK, and ABS

In thermoplastic extrusions, Keller Plastics extends beyond polycarbonate extrusion to materials like Nylon, PEEK, and ABS—each chosen for its distinct properties that address specialized industry needs. Our strategic selection of these materials is a testament to our commitment to delivering comprehensive solutions from standard applications to extreme conditions.


Known for its exceptional durability and abrasion resistance, Nylon is indispensable in applications requiring robust performance. We utilize diverse types of Nylon and specialty grades like Nylon 11, Nylon 12, and Amorphous Nylon, which are clear and suitable for applications needing optical clarity. These materials are ideal for creating tough, impact-resistant products like fishing lines and weed trimmer lines.


Esteemed for its high thermal stability, PEEK serves in environments requiring endurance against extreme heat, often in aerospace and automotive applications where materials must withstand temperatures up to 482°F (250°C). PEEK’s role in these sectors underscores its value alongside polycarbonate.


ABS excels in applications where good impact strength, rigidity, and a high-quality finish are necessary. Beyond its use in automotive components, ABS is advantageous for creating durable household appliances and can also be electroplated for aesthetic enhancements. This material’s versatility makes it suitable for various products, including protective casings and intricate consumer electronics.

By continuously adapting and expanding our material capabilities, we provide not just products but comprehensive solutions that enhance performance and functionality across multiple sectors. 

The Polycarbonate Extrusion Process

At Keller Plastics, the polycarbonate extrusion process is meticulously engineered to produce materials with exceptional qualities tailored for demanding applications. This method ensures polycarbonate profiles exhibit superior electrical insulation and light transmittance rates ranging from 86-90%, crucial for both aesthetic and functional purposes. 

  1. Drying and Pre-Treatment: Essential to preventing defects, our precise drying process removes moisture that can compromise the polymer’s performance. This step is crucial for maintaining the high-impact strength polycarbonate is known for.
  2. Extrusion with Flame-Retardant Properties: We incorporate advanced additives to achieve flame-retardant properties without sacrificing transparency. This makes our polycarbonate ideal for safety-critical applications, such as in the transportation and construction industries.
  3. Customization of Profiles: Our extrusion process allows for adjustments in wall thickness and flexibility, reducing material use by up to 25% while retaining robust properties. This capacity for customization is particularly advantageous for projects requiring unique structural adaptations.
  4. Quality Control and Testing: Every batch of extruded polycarbonate is rigorously tested to meet stringent industry standards, from thermal stability up to 250 degrees Fahrenheit to resistance against solvents and common stains like inks and cosmetics.

Our polycarbonate extrusion process not only adheres to high manufacturing standards but also supports environmental sustainability by integrating eco-friendly practices. By optimizing material use and enhancing product longevity, we help clients achieve their goals with minimal environmental impact. Keller Plastics remains at the forefront of extrusion technology, continuously advancing our processes to meet the evolving needs of our clients with precision and reliability.

Advancing Technology with Nanotechnology in Polycarbonate Profiles

Keller Plastics leads the way in incorporating nanotechnology into polycarbonate profiles, a revolutionary approach that significantly enhances the material’s microstructure. By embedding nanoparticles into the polycarbonate matrix, we achieve unmatched improvements in scratch resistance and UV protection for outdoor and long-term applications. This technology not only bolsters the mechanical properties of polycarbonate but also its optical clarity, making it ideal for high-end optical components and transparent armor.

Nanotechnology also facilitates the creation of lighter materials with enhanced strength for various uses, such as protective gear in sports and advanced filtration systems. These applications leverage the enhanced durability and precise dimensional stability provided by our nanotech-infused polycarbonate, delivering products that perform reliably under rigorous conditions.

Innovative Custom Polycarbonate Extrusion Profiles for Specialized Applications

Leveraging our advanced technology and material science expertise, we create polycarbonate profiles widely used in robust applications, including football helmets, exit lights, bulletproof glass, skylights, and firefighting equipment. These applications benefit from the material’s inherent properties like superior impact strength, which allows for thinner walls without losing structural integrity, and flexibility that resists denting and kinking. 

Our innovative polycarbonate extrusion techniques enable us to meet diverse industry needs with precision and reliability. Additionally, the versatility of our polycarbonate allows for applications in protective eyewear and electronic device casings, where durability and clarity are paramount. Each profile is engineered to maximize both functional performance and aesthetic appeal, meeting the specialized demands of our clients.

Eco-Friendly Manufacturing with Recycled Clear Polycarbonate Extrusion Profiles

Recycling clear polycarbonate not only preserves natural resources but also enables Keller Plastics to craft innovative products that merge functionality with environmental responsibility. By transforming recycled materials into high-performance items, we demonstrate our commitment to sustainable development while meeting the precise needs of our clients.

  • Architectural Elements: Utilizing recycled polycarbonate, we fabricate structural components such as noise-reducing sound barrier panels and atrium roofing, which benefit from the material’s strength and transparency.
  • Medical Device Components: We produce clear, durable parts for medical devices, where sterilizability and chemical resistance are paramount, ensuring safety and longevity in demanding healthcare environments.
  • Public Transportation Fixtures: Recycled polycarbonate is used to create durable, vandal-resistant seating and clear, informative signage for buses and trains, enhancing passenger experience while supporting public sector sustainability goals.

These products exemplify how Keller Plastics integrates eco-friendly materials into diverse industries, maintaining high quality and supporting clients’ sustainability targets without compromise.

At Keller Plastics, we not only adhere to industry standards but also redefine them through innovative practices in polycarbonate extrusion. Our commitment to precision, sustainability, and technological advancement ensures that each project is not just a transaction but a step towards a more efficient and sustainable future. As we continue to push the boundaries of what can be achieved with polycarbonate and other advanced materials, we invite you to join us in this journey to transform industries and exceed expectations. 

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