Arlon self-adhesive vinyl products are compatible with polycarbonate (Lexan®), acrylic, and modified acrylic substrates. However, when applying the film to polycarbonate, it is critical to allow the material to pre-dry before installation.
In the sign and graphics industry, "outgassing" is often used as a generic term for any trapped gas, moisture, or volatiles that cause bubbles under vinyl.
When installers say:
"Let the polycarbonate outgas"
they often mean:
- Remove protective masking.
- Let the sheet acclimate.
- Allow moisture to escape.
- Reduce the potential for bubbles after installation.
They are not necessarily referring to VOC emission in the scientific sense.
SABIC provides a comprehensive LEXAN™ Sheet Processing Guide that recommends pre-drying polycarbonate sheets in an oven at approximately 120°C (250°F). The recommended drying time varies depending on the sheet thickness to ensure that absorbed moisture is removed prior to processing. Lexan Sheet
According to Plaskolite, pre-drying polycarbonate sheets for a minimum of one hour at 250°F (121°C), referred to as "flash drying," promotes a dry surface that is conducive to good film adhesion. This process allows absorbed moisture within the polycarbonate to evaporate before the application of pressure-sensitive film. [plaskolite ]
If the sheet is not properly pre-dried, moisture can become trapped beneath the film and may lead to bubble formation after installation, particularly when the graphic is exposed to direct sunlight or elevated temperatures. [sabic.com]
Because polycarbonate is hygroscopic and can reabsorb moisture from the surrounding environment, proper sign-face construction is also important. Drain holes or breather vents can help moisture escape, while maintaining an air gap between the polycarbonate and the backing surface promotes ventilation and reduces moisture accumulation. Applying the film shortly after the sheet has cooled can further minimize the risk of moisture-related adhesion issues.
Tech Solution Group
August, 2026