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How to Glue Metal to Lexan Bodies

Nathan Fisher

Lexan is a polycarbonate resin thermoplastic used in many manufacturing applications. Because of its high tensile strength, durability and light weight Lexan is used in products ranging from CDs to spacesuits. If you need to bond Lexan to a different material, such as metal, it is crucial to use an adhesive recommend for both surfaces.

Gluing dissimilar surfaces requires an adhesive designed for both materials.

Step 1

Select a two-part epoxy rated to provide adhesion for both metal and polycarbonate plastic materials.

Step 2

Rinse all Lexan and metal surfaces, that will be bonded, with water to remove any loose dust or dirt. Wash the surfaces with soap and water, if needed, to remove heavy buildup. Dry the surfaces thoroughly with a soft towel. Apply alcohol to a dry cloth towel and gently rub the metal and Lexan surfaces to be sure there is no soap residue to interfere with the adhesive.

Step 3

Mix the two-part epoxy, in the mixing cup, according to the manufacture’s instructions.

Step 4

Apply the mixed epoxy to the metal and Lean surfaces with the applicator brush. Follow manufacture’s instructions precisely when applying the epoxy. For some applications some epoxies will require you to coat both of the surfaces, while other epoxies may only require coating one of the surfaces.

Step 5

Hold or clamp the two surfaces together for the time specified in the manufacturer’s instructions.