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No-Spalling Bulletproof Laminated Polycarbonate Panel

PC+TPU Laminated | Impact Resistance | No Spalling Bulletproof 
PC (polycarbonate) and TPU composite materials are the core system for manufacturing high-grade transparent bulletproof, blast-resistant and hurricane-resistant transparent components. The design of this composite structure aims to achieve functional complementarity: the PC substrate, with its high strength and rigidity, provides the main ballistic impact absorption capacity; while the TPU film serves as a key intermediate adhesive layer, offering excellent ductility, tear resistance and impact strength.

What is Bulletproof Panels?

In the field of transparent bulletproof and anti-riot panels, the primary technical approaches center on several high-performance plastic materials and composite glass systems. The key advantage of these materials is their exceptional impact resistance, enabling effective absorption of kinetic energy from ballistic projectiles or violent impacts while maintaining excellent optical transparency.The following outlines the common types of transparent bulletproof and anti-riot panels along with their respective characteristics.
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Bullet-Resistant Laminated Polycarbonate 
  • This is currently the most popular and widely used form of bulletproof plastic sheeting on the market and regarded as the best anti-allistic panel material due to its unique advantage of non-Splashing performance.
  • Polycarbonate itself is a high-strength thermoplastic, with a strength approximately 250 times that of ordinary glass. To achieve ballistic protection, it is usually made into a multi-layer laminated composite sheet .
Bullet Resistant Laminated glass
 
Laminated Glass+Polycarbonate+Innerlayer
  • Laminated glass is one of the traditional bulletproof glass solutions and is often regarded as an alternative to bulletproof glass systems along with polycarbonate.
  • It is composed of two or more pieces of glass with a tough plastic interlayer (usually PVB or SentryGlas Plus) in between. When hit by a bullet, the interlayer can absorb the impact energy and prevent penetration.
     
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Bullet-Resistant Acrylic
  • Acrylic (Plexiglass) is also a commonly used transparent plastic safety material,but mostly been used as interlayer of the laminated panels.
  • After special treatment, acrylic can also reach bulletproof levels. It is more resilient than ordinary glass, but compared to polycarbonate, its cost is usually lower, but it is slightly inferior in strength.
     

Why Choose No Spall Bulletproof Laminated Polycarbonate Sheet?

No spalling property is a crucial step in upgrading bulletproof materials from "preventing penetration" to "ensuring personnel remain unharmed". It is the ultimate guarantee of the safety of modern bulletproof transparent materials.The reasons why the no spalling property in bulletproof transparent materials is becoming increasingly important can mainly be attributed to the following points, all of which are related to maximizing personnel safety and enhancing the applicability of the materials:

Core objective: Protecting the safety of personnel behind the bulletproof material

"Spalling" refers to the phenomenon where, upon impact of a bullet or high-speed projectile on the front surface of a bulletproof material, fragmentation and flaking occur on the back surface (the side facing the protected personnel), generating high-speed flying debris (typically fragments of glass or composite materials).
  • Fatal secondary injury
Even if the bulletproof material successfully blocks the penetration of the projectile, if a large number of high-speed splinters are produced on the back of the bulletproof surface, these splinters themselves have great kinetic energy and may cause serious or even fatal secondary injuries to the protected personnel, such as piercing the skin, eyes or vital organs.
The non-splatter performance ensures that even in the event of successful bulletproofing, the back surface of the bulletproof material remains intact or only undergoes minor, non-high-speed deformation, thereby eliminating the risk of such secondary injuries.
  • Maintain visual acuity and operational ability
In military, police vehicles or important security sites, the main function of bulletproof transparent materials (such as armored windows) is to enable the personnel inside to observe the external environment while defending themselves and carry out counterattacks or operations.
Severe splashing not only can cause injury but also instantly obstruct vision, making it impossible for operators to clearly see the target or drive at critical moments. The no-splashing performance helps maintain a certain degree of clear vision even after being hit.
 

 Technical Trends :Limited clarity loss after being attacked +no fregments from secure side

  • Composite Materials and Lightweighting Demands
Modern bulletproof transparent materials increasingly adopt multi-layer composite structures (such as glass/polycarbonate/polyurethane/laminated) to achieve a lighter and thinner bulletproof effect.
In these composite structures, the design of the backstop surface (typically an organic transparent layer such as PC or PU) is crucial. It needs to have excellent toughness and energy absorption capacity to capture and suppress all fragments, ensuring no splashing. With the increasing demand for lightweighting, the performance requirements for backstop surface materials are also getting higher.
  • More stringent protection standards
Modern bulletproof standards (such as EN 1063 in Europe and UL Level in the United States) have increasingly clear and strict requirements for "no spall". Many high-level bulletproof requirements (such as B6, B7 or advanced military applications) usually require "No Spall" or the use of specific "backing layers" to ensure this performance.
In bidding and procurement, the ability to prevent spatter has become an important indicator for measuring the safety level of materials.
 

No Spall Bulletproof Laminated Polycarbonate vs Traditional Bulletproof Material

Proterity No-Spall Transparent Bulletproof Panels Traditional Transparent Bulletproof Panels
Secure Side Condition The back side remains intact or only undergoes slight deformation. Spalling will occur on the back face, resulting in fragmentation and high-speed splashing of fragments.
Personnal Safety
(A person standing directly behind the bullet-resisting barrier)		 Extremely low risk.
After successfully blocking penetration, there is no risk of secondary injury to the internal personnel.		 High risk.
Fragment splash is the main source of secondary injury, which may cause serious harm to the eyes or body.
Construction The secure side surface is equipped with a special explosion suppression layer or fragment capture layer. It is usually a highly resilient organic material, such as thick polycarbonate (PC) or polyurethane (PU). The structural design focuses more on the penetration resistance of the outer glass layer and the intermediate bonding layer, but pays insufficient attention to the treatment of the back face.
Performance Criterion Complies with high safety grade standards (typically requiring puncture resistance and no splashing). Only meets the anti-penetration requirements. In some lower-grade standards, a certain degree of splashing is allowed.
Total Cost Comparetively higher cost because it requires additional special high-toughness backing materials and a more complex bonding process. Relatively low.
Application Suitable for high-risk environments, such as military vehicles, police shields, cash transport vehicles, VIP cars, and guard posts of important facilities. Suitable for low-risk environments or situations that only require the minimum protection standards.
 

The Key Differences in Structure and Mechanism

The problem of traditional bulletproof plates: spalling

Mechanism

When a high-speed projectile strikes the outer surface of the bulletproof material, a powerful stress wave is generated. This stress wave propagates within the material. When it reaches the free surface of the back face, tensile reflection occurs.
If the tensile stress exceeds the tensile strength of the material (the tensile strength of glass is much lower than its compressive strength), it will cause the back surface of the material to break, and the fragments will fly out towards the protected space at extremely high speeds (hundreds of meters per second).

Consequence

Even if the bullet does not penetrate, these high-speed fragments may scatter like shotgun pellets towards people, causing serious injuries.
 

Solution for Non-Splatter Bulletproof Plates: Spall-Liner

The non-splatter design is achieved by adding one or more layers of special high-toughness organic materials to the innermost side (the back side facing the impact) of the composite plate. This layer is usually called:
  1. Fragment capture layer (Spall-Liner/Spall Shield)
  2. Anti-spall layer(explosion suppression Layer）

What it the function of the explosion suppression layer?
  • Absorb residual energy: Completely absorb the residual kinetic energy after it passes through the glass layer to prevent it from penetrating further.
  • Fragment capture: Most importantly, it acts like a net with its extremely high toughness and ductility, firmly adhering or capturing all the high-speed fragments flying inward from the front glass layer on its surface, preventing them from entering the protected space.
  • Buffer deformation: At the moment of being hit, it allows itself to undergo a certain degree of plastic deformation (bulging) to disperse and absorb energy, but it will not shatter itself.
Therefore, the splash-proof plate is the mainstream of modern bulletproof transparent technology because it truly achieves the ultimate goal of "personal safety", rather than merely " the material not being penetrated".

How is No Spall Bulletproof Laminated Polycarbonate Sheet Produced?

Processing Step of Laminated Polycarbonate Sheet

1. Material Selection & Preparation

This initial stage focuses on selecting and preparing the core materials that contribute to the panel's ballistic and optical properties.

Polycarbonate (PC) Sheet: Select High Luminous Transmittance sheets, prioritizing High Impact Resistance for the main structural component.

Thermoplastic Polyurethane (TPU) Film: Select TPU with High Strength, High Toughness, and Excellent Bonding Strength to serve as the interlayer adhesive and the key component for absorbing residual energy and preventing spalling.

 

2. Lamination Process (Layering and Bonding)

This is the main manufacturing stage where the material layers are bonded under controlled conditions to form the composite structure.

Hard Coating: Apply a Hard Coating to the external surface of the Polycarbonate Sheet to enhance scratch resistance and protect the surface.

Layup & Bagging: Carefully stack the treated PC sheets and TPU films (Layup) and then seal the layered structure within a vacuum bag (Bagging).

Air Voids Removing: Apply vacuum pressure to the bagged assembly to thoroughly remove all residual Air Voids between the layers, ensuring a perfect bond later.

Move into Autoclave: Transfer the prepared assembly into the Autoclave chamber.

High Temperature & High Pressure Lamination: Subject the material to a Production Standard cycle within the autoclave. This involves operating in a Dust-free Workshop environment, applying High Temperature (rising gradually from 40℃ to 130℃) and High Pressure for several hours to permanently bond the layers.

 

3. Performance Testing

After lamination and cooling, the finished panels undergo a series of rigorous tests to confirm they meet both protective and optical standards.

Cutting: The finished panels are Cut to the required final dimensions.

Ballistic and Impact Testing:

Impact Test: General resistance test.

Bulletproof (NIJ/GA) Test: Standard ballistic testing against specific threat levels.

Falling Ball Test: Assessing resistance to blunt force impact.

Optical Properties Testing:

Haze Test: Measure the Haze Value to ensure the panel maintains high transparency and minimal light diffusion.

Weatherability Testing:

UV/Temp/Humidity Cycle: Testing the durability and stability of the material under various harsh environmental conditions (UV exposure, temperature swings, and humidity) to ensure long-term performance.

Installation Test: Final inspection simulating the Installation process into the intended vehicle or structure.

How To Choose A Right Bulletproof Laminated Polycarbonate Sheets

A Quick Guide to Demand Matching

Since all bulletproof and impact-resistant materials are highly customized. Every sample we provide is optimized for specific threat levels and application environments. To avoid us offering a 'general-purpose' sample, which could lead to inaccurate test results and waste your time and resources, a clear and quick demand matching guide is particularly important and necessory.
 

Step 1: Define the protection objective - What does your client want to "block"?

High-performance bulletproof panels are designed for specific threats. Please help us identify the core security goal of the end client, which is the primary condition for determining the product grade.
TSS UL 752 Standard for Bullet Resistant Barrier Testing chart_01

Step 2: Evaluate the application environment - Where will your product be used?

In addition to the US NIJ standard, there are multiple international and regional standard systems for bulletproof testing, which are applicable to different application fields (military, security, construction, vehicle protection, etc.).
 

Step 3: Confirm the testing standards-Which standard is most concerned by clients?

The application environment determines the physical properties of the material and the final formula. Weight, clarity and durability are the key factors that need to be locked in at this stage.
Standard System Zone of Application Applicable materials Found Range Application
NIJ 0108.01 North America Bulletproof Panels/Glass Type I–IV Police/Military
UL 752 North America Various Bulletproof Components Level 1–10 Civilian / Architectural
EN 1063 European Union Bulletproof Glass BR1–BR7 Buildings and Vehicles
STANAG 4569 North Atlantic Treaty Organization Armored System Level 1–6 Vehicle Protection
GB/T 17840 China Bulletproof Laminated Glass 1–7 Level Public Security / Security and Protection
ISO 16935 Global Security Glass Same as EN System Common Use

 

Ballistic test setup

 

Step 4: Budget and Scale - "How much money" and "How much quantity"?
Combining performance with commercial feasibility. Clear budgets and quantities enable us to directly offer the most market-competitive prices.
Please use the above framework to collect information about the end customers. Once you have filled in the key data of these three dimensions, please contact us immediately info@polyteching.com or WhatsApp +86 1380150389.
We promise that upon receiving your clear list of requirements, we will match the most suitable configuration plan, customized sample preparation plan and initial quotation for you within 24 hours.

 

Application of No Spall Bulletproof Laminated Polycarbonate

  • 300000069

     

    Architectural

     
  • 300000135

     

    Impact Resistant Shield

     
  • bank security bulletproof glass

     

    Security Window

     
  • Laminated Polycarbonate for Vehicle Armoring(1)

     

    Armored Vehicle

     
  • No Spall Polycarbonat-Window Panel for Machine(1)

     

    Machine Window

     

Installation Instructions

Installation Best Practices

The connection between bulletproof panels and their frames and walls is the most crucial link in the entire bulletproof system.

The matching of the frame and components is the core

  • System integrity: Strictly use the system-tested and certified matching frames (such as steel or aluminum alloy structures) to ensure that the frame's bulletproof level is consistent with the panels. Do not use ordinary building frames, as they are the weakest point of the entire bulletproof system.
  • Margin protection: Ensure that the edges of the plate are fully covered and fixed by the frame. In design, the area where the bullet is most likely to penetrate is often the junction of the plate and the frame.

Fixing and Anchoring Are Key

  • High-strength fasteners: High-strength, shear-resistant fasteners (bolts/screws) must be used and installed at the intervals specified in the design.
  • Deep anchoring: Ensure that the frame is securely anchored to the load-bearing walls or columns of the building structure. Incorrect anchoring may cause the entire bulletproof component to fall off the wall when subjected to continuous shooting or heavy impacts.

Avoid Stress Damage

Precise Tolerance: During installation, it is essential to ensure that the size of the panel precisely matches the size of the frame to avoid internal stress caused by forced squeezing or twisting. Stress concentration may lead to early cracking of laminated glass or polycarbonate, thereby reducing the bulletproof performance.
Sealing treatment: Use weather-resistant and flexible sealant to seal the panels with the frame to prevent water infiltration, delamination of the interlayer and eliminate vibration.

Maintenance and Care

Daily cleaning and long-term maintenance 

Proper maintenance not only keeps the clarity of the board but also extends its service life and maintains its protective performance.

1. Correct Cleaning Method (Cleaning)

  • Avoid Abrasives: Use only neutral soap water or a dedicated cleaner. Do not use cleaners containing ammonia, alcohol, solvents, or abrasive particles, as these chemicals can corrode the polycarbonate coating or damage the glass laminate.
  • Use a soft cloth: When cleaning, use a soft cotton cloth or microfiber cloth. Avoid using rough sponges or brushes to prevent scratching the surface of the board, especially polycarbonate boards.
  • Immediate treatment: Any splashed strong acid, strong alkali or paint should be immediately rinsed with a large amount of clean water.
 

2. Regular Inspection and Professional Maintenance (Inspection)

  • Inspect the laminate: Regularly check the interior of the laminate for signs of delamination, bubbles or fogging. These are common indications of laminate failure and should be immediately reported to a professional for maintenance.
  • Inspect the surface: Check the outer surface of the plate for deep scratches, cracks or obvious impact marks. Severe damage may reduce the bulletproof capability of that area.
  • Inspection framework: Check if all fasteners are loose, and whether the framework has rust, deformation or gaps at the connection with the wall. Any structural weakness of the framework may endanger the safety of the entire system.

No Spall Bulletproof Laminated Polycarbonate Sheet FAQ

  • 1. What is "No Spalling" performance, and why is it important?

    A "No Spalling" refers to the absence of fragmentation or peeling on the back side (the side facing the protected person) of the armor when struck by a projectile. Importance: Even if the armor successfully stops the projectile's penetration, the fragments (spall) created can cause severe secondary injuries (e.g., eye or face damage) to personnel inside. No-spalling performance is the ultimate safety guarantee to ensure the personnel remain unharmed.

  • 2. How is the no-spalling feature achieved?

    A It is achieved by incorporating a special layer of high-tenacity organic material (such as thick Polycarbonate (PC) or Polyurethane (TPU) film) on the innermost side (the back side) of the composite structure. This layer is often called a "Spall Shield" or "Catch Layer," and its extreme toughness and ductility absorb all residual energy and capture any fragments generated by the impact on the outer layers.

  • 3. If PC has inferior optical performance to glass, why use Pure PC Composite?

    A The main advantage of Pure PC Composite is its extremely low weight and superior impact toughness. In scenarios with strict weight limits or a need for material flexibility and non-brittleness (like police riot shields), pure PC is the preferred choice. While its transmittance is slightly lower than glass, modern PC surfaces are treated with a hard-coat finish to improve optical stability and scratch resistance.

  • 4. Why is PC/Glass Composite heavier than Pure PC Composite?

    A This is due to the density of glass, which is significantly higher than that of Polycarbonate (PC). To achieve the same ballistic rating (e.g., NIJ Level III), the glass composite panel must use multiple layers of thicker glass to dissipate the bullet's initial energy, thus substantially increasing the total weight.

  • 5. Is the thickness of no-spalling armor fixed?

    A No, it is not. The armor thickness is custom-designed based on the client's required protection level (e.g., resistance against handguns, rifles, etc.) and the specific threat type. A higher rating (e.g., upgrading from NIJ IIIA to NIJ III) requires more material layers and a greater overall thickness.

  • 6. Can the armor be reused after being struck by a projectile?

    A It is strongly discouraged. Even if the no-spalling panel successfully stops the penetration, the internal structure (such as the glass layers or bonding interlayers) in the impact area is severely compromised, and its energy-absorbing capacity will be significantly reduced. For safety assurance, any bulletproof material that has been struck by a projectile should be replaced as soon as possible.

  • 7. How should a client decide between PC/Glass and Pure PC solutions?

    A
    Priority 1 (Weight): If the client has extremely strict weight requirements and can tolerate slightly lower scratch resistance, choose Pure PC Composite.
     
    Priority 2 (Clarity & Durability): If the client requires long-term clarity, high scratch resistance, and optical stability, and has a higher weight tolerance, choose PC/Glass Composite.
     
    Budget: Pure PC Composites can sometimes be more expensive than high-performance PC/Glass Composites due to complex production and hard-coating processes.
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