Can I chuck in my twopennerth?
Polycarbonate is made to flex - that's its strength and it really will take some breaking unless it's been fixed incorrectly. There are some very good technical working sheets available from the various manufacturers and distributors such as Amari Plastics (no connection). For any sceptics, just get a small piece, lay it flat on a smooth(ish) surface and belt it with a hammer. It'll dent but won't break unless faulty!
There are minimum size frame rebates recommended and if drilling for mechanical fixing I'd seriously recommend holes no closer to the edge than 12mm. The holes have to be carefully drilled also as micro cracks are a weakness and always oversize so the poly can expand around the fixing. Note also that some silicones attack and degrade the polycarbonate and you should always use one suggested for the material.
It's many years since I was in the industry but at the time there was a 3m brand d/s tape available about 10 wide especially for fixing into older bus shelter frames and it was exceptionally strong and reliable.( I might still have some in a drawer ) There was one instance where yobs tried everything to break a large 6mm bus shelter panel without success so used a blowtorch which was, to my great amusement left stuck firmly in the hole they had managed to burn throughthe poly. #-o :lol:
For demonstratiopn purposes (Lexan) we used to fix a 1200 x 600 x 6mm sheet into a timber frame. 20mm rebates and held in place only by pinned mouldings then offer all and sundry the opportunity of attacking it with a very large mel / hammer. It would mark and scratch very easily but never had a breakage.
Normally 4mm would be quite adequate but use 6mm if you want belt and braces. If you make small screens which will fit into a domestic oven they can be heated until pliable and clamped around formers or even "blown" to shape btw. Don't normallytry to heat with a flame or element as it just degrades the surface, though it is possible with care.
I might have some info tucked away in the loft if you're stuck.
Bob
PS Just done a very quick search and here's one I found for Makrolon
http://www.curbellplastics.com/technica ... krolon.pdf