PET vs Polycarbonate: 8 Questions We Answer at Eaton

FAQ: the questions we actually get

I've handled 200+ rush orders for plastic sheets and rolls at Eaton. In that time, I've learned that buyers don't want a sales pitch. They want straight answers. So here are the questions I get asked again and again, answered the same way I'd answer a client on the phone.

1. What's the difference between PET and polycarbonate sheets?

PET, or polyethylene terephthalate, is the clear plastic used in food packaging, blister packs, and printed displays. It's food-safe, has good clarity, and resists scratching better than you'd expect. Polycarbonate is a tougher, impact-resistant material used for machine guards, safety glazing, and parts that take abuse. It handles heat better, but it costs more and scratches more easily.

• PET: lower cost, good scratch resistance, food-safe, less impact strength.
• Polycarbonate: much higher impact strength, higher heat tolerance, more expensive, softer surface.

Honestly, the answer depends on what 'enough' means for your application. If it's a display or a packaging insert, PET is likely enough. If it's a guard that might get hit, don't cheap out—go with polycarbonate.

2. Is PET sheet safe for pet mice and small animal cages?

Yes, PET is generally safe for animal enclosures. It's BPA-free, doesn't off-gas, and cleans up well. But I'd add a caution: safe doesn't mean chew-proof. A bored mouse can scratch or chew through PET if it gets a hold of an edge. Polycarbonate is much harder to chew through, which is why many custom small-pet cages use PC panels.

If you're building a cage for pet mice, PET works for the clear walls—it's affordable and easy to wipe down. For a permanent enclosure or a part where chewing is a real risk, polycarbonate is the better investment. We cut both to size, and yes, we can rush a small order if your project is stuck.

3. What is 'Eaton bathtub resin'? Do you sell it?

I've seen that term come up in searches, and I think it's causing some confusion. Eaton—the company I work for—makes PVC, PET, PETG, PS, PP, and ABS sheets and rolls. We don't make a product called 'Eaton bathtub resin.'

If you're thermoforming bathtubs or shower trays, the plastics you're likely looking for are acrylic or PETG. PETG is popular because it forms cleanly, holds color well, and resists bathroom chemicals. If a supplier quotes you 'bathtub resin' without naming the exact polymer, ask them to spell it out. In my experience, vague names are where hidden costs creep in.

4. Are Eaton hydraulic hose fittings part of your product line?

No—we don't make hydraulic hose fittings. That's a different Eaton. But while people are here searching for 'hydraulic hose material,' I can give you the short version: hose material has to match the fluid, pressure, and temperature. Common options include polyamide, polyurethane, rubber, and PTFE. For mineral oils at moderate temperatures, polyurethane is often a solid balance. For high heat, PTFE is hard to beat.

If you need plastic sheets for a machine guard, a control panel, or a display around hydraulic equipment, that's what we do. If you need actual Eaton hydraulic hose fittings, I don't want you to waste time on a sheet manufacturer—go directly to an industrial distributor.

5. Why does your quote change when I adjust the specs?

Because thickness, material grade, color, surface finish, and quantity all drive manufacturing cost. That sounds obvious, but the frustrating part is the suppliers who quote low to win the purchase order, then add on 'setup,' 'color matching,' or 'rush' charges later. You'd think written specifications would prevent that. They don't.

At Eaton, we put the whole price in the quote: material, cutting, color matching, packaging. If something isn't included, we say so up front. That's what transparent pricing means to me. And when I'm buying anything for myself, I always ask the question that saved me after a bad assumption once: 'What's NOT included?' I once assumed a quoted price included cutting. It didn't. That little assumption cost us an extra $150. Trust me on this one.

6. Can you really deliver a rush order in 48 hours?

Sometimes. In March 2024, a client called at 4 pm and needed 300 printed PET sheets for a trade show panel the next morning. Normal turnaround was five days. We had the raw material in stock, the production manager stayed late, and we delivered at 6 am. We charged a 30% rush fee on top of the standard price. The client's alternative was losing a booth that cost them $12,000. They paid without arguing.

I have mixed feelings about rush fees. On one hand, they feel like a punishment for bad planning. On the other hand, I've seen what a rush order does to a production schedule—it's not just 'move us to the front of the line.' We're pulling people off other jobs, slowing down deliveries, and adding risk. So the premium is real.

But I won't promise what I can't deliver. Years ago, I skipped a final proof check because it was 'basically the same as last time.' It wasn't. We shipped the wrong shade of blue, and the rerun cost $400. That mistake taught me to build a 24-hour buffer into any deadline I quote.

7. How do I match Pantone colors on plastic sheet?

If your project is brand-critical, the industry standard is Delta E < 2 for color tolerance. Delta E of 2 to 4 is visible to trained eyes, and above 4 is noticeable to most people. Reference: Pantone Color Matching System guidelines. We use Pantone references for custom colors on every job that needs them.

A caveat: printed plastic won't look exactly like a coated paper swatch because the substrate reflects light differently. Always ask for a physical sample before a large run. And if your design has small text or detailed graphics, keep it at 300 DPI at final print size. Anything less, and the edges will look soft.

8. What thickness should I order?

This is the question to ask before getting a quote. For thermoforming, 0.5 mm to 2.0 mm is common. For signs and displays, 2.0 mm to 6.0 mm is typical. For binding covers, 0.4 to 0.8 mm works. But the right answer depends on rigidity, weight, and how the part is going to be used. I'd rather ask a few dumb questions than have you order the wrong thing.

If you're comparing PET vs polycarbonate, or just need a sheet that actually fits the job, send us the details. We'll tell you what we'd do, what it costs, and what's not included. If we can't meet your deadline, we'll say that too.