Introduction: The Frame Material Behind High-Performance Sports Eyewear

When it comes to sports sunglasses, most people instinctively focus on lenses—UV protection, polarization, tint, etc. But for B2B buyers, brand owners, and OEM project developers, the material of the frame plays an equally critical role. After all, the frame determines whether the eyewear can survive impact, provide long-term comfort, and meet the design expectations of modern, active consumers.

In the world of sports eyewear manufacturing, polycarbonate (PC) has emerged as one of the most practical and reliable materials for sunglass frame production. Known for its lightweight nature, high impact resistance, and superior molding precision, PC is widely used in cycling sunglasses, tactical eye protection, outdoor adventure frames, and other performance-driven designs.

But what makes PC truly suitable for mass production? How does it compare with other materials like TR90, nylon, or ABS? And most importantly, is it the right choice for your brand’s next product line?

As a sunglasses manufacturer with over 15 years of OEM/ODM experience, Eyewearbeyond has worked with global wholesalers, independent brands, and B2B importers across more than 30 countries. We operate 5 production lines dedicated to eyewear manufacturing and have developed and tested hundreds of PC-based sunglass frame models for real-world markets.

We’ve seen firsthand how different materials—PC, TR90, nylon, acetate—perform on the production line and in the field. This article isn’t theory—it’s based on direct manufacturing experience, client feedback, and practical performance data from global shipments.

In this article, we’ll explore everything you need to know about PC as a frame material for sports sunglasses—from technical properties to production methods, and from cost-efficiency to market suitability—so you can make the best decision for your eyewear business.

What Is PC (Polycarbonate) Material?

Polycarbonate (PC) is a high-performance thermoplastic polymer widely known for its strength, clarity, and excellent processability. Originally developed for use in aerospace and defense industries, PC has since become a staple material in a wide range of consumer products—from smartphone components to safety helmets and, increasingly, sunglass frames.

When used in sports eyewear, PC offers a rare combination of rigidity and lightweight strength, making it ideal for frames that must maintain their shape under stress but remain comfortable during extended wear. Unlike more flexible materials such as TR90 or nylon, PC frames offer structural integrity, which is crucial for frame designs that prioritize stability and form retention.

Here are some key physical and mechanical characteristics of PC that matter for eyewear manufacturing:

From a manufacturing perspective, PC offers a fast, cost-effective injection molding process, allowing eyewear factories to create precise, complex frame geometries at scale. For wholesale buyers and private label brands, this means access to stylish, durable sports frames with consistent quality across batches.

Unlike acetate or stainless steel—which require multiple stages of manual polishing or adjustment—PC frames are mostly “machine-finished”, reducing human labor, speeding up production, and lowering overall unit costs.

Most importantly, PC’s balance between structural rigidity and moderate flexibility makes it ideal for sports sunglass frames that need to endure real-world usage conditions like drops, pressure, sweat, and UV exposure.

Why PC Is Chosen for Sports Sunglass Frames

When designing or sourcing sports sunglasses, the choice of frame material directly affects performance, user experience, and production efficiency. Polycarbonate (PC) is not the only option on the market, but it offers a compelling mix of mechanical strength, processing convenience, and cost control that make it a go-to material for many mid-range and performance-driven sunglass frames.

Below are the key reasons why PC stands out as a smart choice in this category:

1. Outstanding Impact Resistance

Sports eyewear must endure sudden shocks—whether it’s being dropped on concrete, hit by debris, or squeezed in a packed gym bag. PC’s high impact resistance means it won’t crack or shatter easily, making it an ideal choice for activities like:

• Cycling
• Mountain biking
• Trail running
• Tactical and industrial work environments

📌 PC can absorb blunt force without structural failure, offering users a high degree of safety—especially important for frames intended for eye protection during active movement.

2. Lightweight Comfort for Extended Wear

PC has a low density (~1.20 g/cm³), which makes the resulting frames lightweight and comfortable, even for larger, wraparound frame designs. In sports scenarios, where users may wear sunglasses for hours, this makes a significant difference:

• Less pressure on the nose bridge and ears
• Reduced frame fatigue over time
• Better balance when paired with heavy lenses (e.g., polarized or prescription inserts)

For brands, this means fewer customer complaints about discomfort or slippage—key for long-term customer retention.

3. Excellent Structural Rigidity

Unlike more flexible materials like TR90, PC offers rigidity and form stability. This is especially important for:

• Full-wrap shield frames
• One-piece athletic designs
• Prescription-compatible sports models

The frame keeps its shape under physical stress and temperature fluctuations—important for maintaining lens alignment and a snug, secure fit even during vigorous movement.

4. Superior Design Moldability

PC’s behavior under high heat and pressure makes it ideal for complex mold designs. It flows well in mold cavities and cools rapidly, enabling:

• Precision molding of nose pads, ventilation details, or textured surfaces
• Seamless integration of thick and thin elements in one frame
• Efficient mass production of high-detail frame shapes

Whether you’re developing a bold, aggressive silhouette or a low-profile runner’s frame, PC delivers on both visual style and mold accuracy.

5. Wide Surface Finishing Compatibility

PC frames support a wide variety of post-molding treatments, such as:

• Rubber coating for grip and anti-slip temples
• Spray painting (glossy, matte, gradient, metallic)
• UV coatings for colorfastness and outdoor longevity
• Hydro-dipping for camo or graphic prints

This versatility allows sports eyewear brands to differentiate their product lines without changing the base frame structure—just the finish and aesthetic. It also means a more dynamic catalog with minimal tooling investment.

6. Color and Branding Flexibility

PC material can be:

• Pre-pigmented before injection
• Dyed post-injection
• Laser-engraved with logos
• Pad printed with brand elements

This gives you control over visual identity—essential for private label brands and marketing-driven collections in the sportswear segment.

7. Balanced Cost and Performance for OEM Orders

Compared to higher-end materials like nylon (PA12) or flexible TR90, PC provides:

• Lower mold wear and tear (longer mold life)
• Shorter cycle times per unit
• Lower defect rates

This makes PC a cost-efficient option for large-scale OEM orders, especially if your eyewear targets the mid-range sports or active lifestyle market.

In summary, PC combines safety, strength, design freedom, and pricing efficiency in a way that few other materials can match. For sports sunglass frame production, it strikes an ideal balance between performance and profitability—something that both independent brands and bulk wholesalers should seriously consider.

Technical Properties That Matter to Manufacturers

For eyewear brands and wholesale buyers working closely with factories, understanding the technical behavior of materials during production is just as important as knowing the marketing benefits. While polycarbonate (PC) offers excellent end-user value, what makes it truly attractive in manufacturing is how well it performs on the production line.

Below are the critical properties and production advantages of PC that manufacturers—and by extension, their clients—should know:

1. Excellent Flowability for Complex Mold Design

PC has superior flow characteristics when melted, meaning it can easily fill molds with:

• Thin-walled sections
• Angular shapes
• Detailed surface textures

This allows designers to incorporate fine grooves, integrated ventilation channels, or sculpted styling into the frame without compromising structural integrity.

⚙️ Result: Greater freedom in frame geometry with fewer manufacturing defects—ideal for bold, high-performance sports designs.

2. Short Cycle Times in Injection Molding

PC can be processed at standard injection molding temperatures of 230–320°C, and its cooling time is faster than more elastic materials like TR90 or nylon.

This means:

• Faster cycle time per unit
• Higher daily output
• Easier scaling of production when demand spikes

✅ For factories like Eyewearglobo with multi-line injection systems, PC frames can be produced in large batches efficiently, with fewer machine adjustments or cooling delays.

3. High Dimensional Stability After Molding

PC retains its shape exceptionally well after cooling. Unlike some flexible materials that shrink or warp slightly after demolding, PC offers:

• Minimal deformation
• Better lens groove consistency
• Superior alignment with shield-type or single-lens designs

This ensures that each frame meets tight tolerances for lens fitting—critical in sports frames where improper alignment can affect comfort and performance.

4. Strong Adhesion with Surface Coatings and Paints

PC’s surface structure is well-suited to:

• Soft-touch rubber coating for grip temples or nose pads
• UV-resistant paint to prevent fading under sunlight
• Pad printing or silk screen for branding elements
• Hydrographic transfer for complex patterns

Unlike slicker materials like nylon, PC holds coatings firmly—meaning your sunglasses maintain visual appeal and brand identity after months of rugged outdoor use.

5. Resistance to Common Manufacturing Pitfalls

Manufacturers favor PC because it:

• Warps less than TR90 in poor temperature environments
• Doesn’t require annealing like some nylons
• Has fewer molding rejects due to its stable shrinkage rate (~0.5–0.7%)

📉 These factors reduce production waste, which translates into lower unit costs and more predictable lead times—two things B2B buyers love.

6. Tooling Longevity and Cost Advantage

PC is less abrasive on molds compared to fiber-filled nylons, which means:

• Longer mold life (important for repeated bulk orders)
• Lower maintenance downtime
• Reduced long-term production costs

For a wholesaler placing thousands of units per quarter, this makes PC ideal for repeated OEM production without frequent mold repairs or replacements.

7. Compatible with Additives and Enhancements

PC can be mixed with additives before injection, allowing for:

• Color masterbatch customization
• UV-stabilizers for extreme sun exposure
• Anti-static or anti-bacterial additives (for special-use eyewear)

This makes it highly customizable for niche product categories like tactical sports eyewear or outdoor safety glasses.

🏭 Eyewearglobo’s Advantage in PC Frame Production

As a Chinese factory with 5 production lines, Eyewearglobo is fully equipped to maximize PC’s manufacturing advantages:

• In-house mold engineering for custom frame designs
• Advanced injection systems for large-batch PC molding
• Dedicated coating/printing workshops for brand customization
• Rigorous QC protocols for each production stage

We help clients optimize their designs for PC production to reduce costs, accelerate time to market, and ensure compliance with global standards (FDA, ANSI, CE).

PC vs. Other Common Frame Materials

Choosing the right frame material for sports sunglasses isn’t just a matter of cost—it’s a strategic decision that impacts product positioning, manufacturing process, and user experience. While polycarbonate (PC) is a solid contender, it’s important to evaluate how it stacks up against popular alternatives like TR90, nylon (PA12), and basic plastics such as ABS or AC.

Let’s take a deeper look at how PC compares across several key factors:

1. Mechanical Performance Comparison

💡 Interpretation:
PC offers a balance between rigidity and impact protection, making it suitable for sports sunglasses that need to hold shape under stress (like shield or wraparound designs). TR90 and nylon are better if extreme flexibility is required—but may lack PC’s form stability.

2. Molding and Design Flexibility

🔧 Insight:
PC outperforms both TR90 and nylon in precision molding—making it ideal for sporty shapes, integrated nose pads, or frames with ventilation details. It also supports faster production cycles, a key advantage for high-volume orders.

3. Surface Finishing & Aesthetics

🎨 Conclusion:
PC is very finish-friendly, allowing brands to build premium-looking sports eyewear at a reasonable cost. For clients who need multiple SKUs with the same mold but different surface effects, PC is a cost-effective solution.

4. Cost Comparison (Material & Production)

💰 Summary:
PC offers mid-range pricing but low reject rates, making it ideal for brands that want stable unit cost and reliable QC without compromising on quality.

5. Best Use Cases by Material

Final Takeaway on Material Comparison

While TR90 and nylon offer more flexibility and higher-end branding potential, PC hits the sweet spot in sports eyewear:
✔️ Strong enough for active use
✔️ Light enough for long wear
✔️ Affordable for large-scale production
✔️ Customizable enough for private-label brands

If your brand values cost control, production stability, and sporty design capability, PC remains a powerful material option—especially when combined with expert tooling and coating partners in China.

Application Scenarios in Sports Eyewear

One of the major strengths of PC (polycarbonate) as a frame material is its versatility across various sports environments. Whether your target customers are cyclists, runners, tactical professionals, or general outdoor enthusiasts, PC offers a durable, customizable, and comfortable solution.

Here’s a detailed look at where PC frames perform best—and where you might consider alternatives:

1. Cycling Sunglasses: Secure Fit Meets Lightweight Stability

Cyclists require sunglasses that:

• Fit tightly without slipping
• Resist impact from wind-blown debris
• Remain lightweight during long-distance rides

✅ Why PC works:
PC frames are rigid enough to grip the head securely, especially when designed with wraparound temples and rubber-coated nose pads. Their lightweight nature helps reduce pressure during hours of wear. PC also supports shield-style lenses, which are popular in cycling.

2. Trail Running & Outdoor Sports: Built for Motion and Endurance

Runners and trail athletes need eyewear that:

• Doesn’t bounce or slide during movement
• Resists occasional drops and collisions with foliage or gear
• Feels light but durable

✅ Why PC works:
PC’s impact resistance and structural stability make it suitable for trail or urban running sunglasses. It’s tough enough to survive the occasional fall while remaining light enough to avoid discomfort during intense training sessions.

3. Tactical and Protective Sunglasses: Rugged & Compliant

This includes eyewear used in:

• Shooting sports
• Law enforcement
• Military-style outdoor gear

✅ Why PC works:
PC frames can be engineered for ANSI Z87.1 impact resistance and matched with safety-grade lenses. The material’s rigid profile supports one-piece designs and can be coated for camouflage or matte black tactical aesthetics.

4. Workwear & Industrial Safety Eyewear: Functional and Cost-Effective

For job-site protection or safety eyewear sold in hardware stores, PC is a smart solution.

✅ Why PC works:
It’s compliant with industry standards, affordable, and works well for bulk orders. Frame designs for this category are often simple, and PC’s fast molding time and low rejection rates make it ideal for this use case.

5. Entry-Level Sports Fashion Sunglasses: Style + Function

If you’re selling into:

• Lifestyle sports brands
• Budget athletic eyewear collections
• Promotional gift packs

✅ Why PC works:
PC allows for bold frame designs, multiple color options, and surface treatments like glossy finishes or mirrored logos. You can make products look sporty and premium without the high cost of TR90 or nylon.

❌ When NOT to Use PC Frames

While PC works great in most sports contexts, there are situations where it may not be the best material:

📌 Design Tip for Brands:

To maximize PC’s potential, match the frame structure to its material strengths:

• Use thicker temples for stability
• Add rubberized inserts for grip
• Avoid thin hinges or ultra-bendable areas (where PC is less forgiving)

In summary, PC frames are a top performer for mid- to high-functionality sports sunglasses, especially where lightweight strength, impact resistance, and manufacturing speed are priorities. With the right design adjustments, they can serve both professional athletes and active lifestyle users.

Business Considerations for PC Frame Production

For eyewear wholesalers, private-label brand owners, and OEM buyers, the choice of frame material is not just about engineering—it’s about profitability, brand positioning, and supply chain efficiency.

Polycarbonate (PC), as a sunglass frame material, offers a unique balance of production stability, cost control, and product performance, making it a strategic option for many sports eyewear businesses.

Let’s look at the business-critical factors that make PC a smart choice (and when it may not be):

1. Lower Entry Barrier for Mold Investment

PC supports high-precision injection molding, which allows:

• Complex designs in single-cavity molds
• Shorter mold cycles (faster ROI)
• Compatibility with standard injection machines (lower factory setup cost)

For small-to-medium brands, this means:

• You can launch new SKUs with less tooling expense
• You don’t need special equipment like for TR90 or nylon
• Faster mold testing and sampling—10-15 days turnaround possible in China

2. Stable Unit Cost for Mass Production

Unlike nylon or acetate, PC offers:

• Lower per-unit cost in 1000–5000 pcs quantities
• High mold endurance (10,000+ injections before maintenance)
• Lower scrap and defect rates (cost-saving in large-scale production)

✅ For buyers with tight pricing margins, PC gives more predictability and repeatability per production batch.

3. Broad Positioning Range for Product Line

PC frames can be positioned as:

• Functional sports eyewear (cycling, trail, running)
• Workwear or tactical gear (with ANSI/FDA compliance)
• Mid-priced fashion sports collections (with color and branding options)

If you’re running a multi-segment product line, PC is a great “middle material”:

• Looks premium enough for display
• Performs well enough for light-to-medium sports use
• Produces profitably enough for wholesalers

4. Customization Potential Without Excess Cost

PC allows for:

• Custom frame shapes (one-piece wrap, shield, hybrid)
• Color flexibility: matte, gloss, clear, neon
• Logo printing or engraving
• Rubber grips or dual-injection ends

All without dramatically increasing production cost. This is ideal for DTC brands and regional wholesalers who want SKU differentiation without breaking the bank.

5. Profit Margin Optimization

PC frames help businesses improve profitability through:

• Shorter production cycles = faster inventory turnover
• Lower post-production defect rates = fewer QC reworks
• Less packaging damage during transit = fewer returns

Also, since PC is more “mass-market” friendly than TR90, many brands can retail at premium price tiers (e.g., $39–$59 USD) while maintaining moderate wholesale cost (e.g., under $5 USD FOB China).

6. Ideal for Clients with These Needs:

❌ When to Avoid PC (Strategically)

💡 Strategic Tip from Eyewearglobo:

If you’re launching a new sports series, consider starting with PC frame designs to test market response. Once successful, upscale to TR90 or nylon for a premium tier. This staged approach controls cost and builds brand depth.

Certification and Compliance

For any brand or wholesaler aiming to sell sports sunglasses internationally—especially in North America, Europe, or Oceania—certification is non-negotiable. Regulatory bodies enforce safety, performance, and environmental standards, particularly when it comes to eyewear used for sports or protective purposes.

The good news: PC (Polycarbonate) frame material is widely recognized, tested, and accepted across major compliance frameworks. When manufactured properly, PC frames can meet or exceed the requirements of most global certifications.

1. FDA Compliance (USA Market)

The U.S. Food and Drug Administration (FDA) requires that all sunglasses sold in the U.S. pass a “drop-ball impact test”, which simulates accidental shock and ensures the frame and lenses can resist blunt force.

✅ Why PC qualifies:

• PC is naturally impact-resistant
• It does not shatter under stress
• Ideal for frames that need to pass basic FDA 21 CFR 801.410 standards

At Eyewearglobo, all PC frames can be tested using the FDA drop-ball method with test reports provided upon request.

2. ANSI Z87.1 (USA Safety Glasses Standard)

For sunglasses used in tactical, industrial, or high-risk sports environments, frames may need to comply with ANSI Z87.1—the U.S. safety eyewear standard.

✅ Why PC is suitable:

• PC frames can withstand high-velocity impact when designed with reinforced temples and hinges
• Easy to pair with ANSI Z87.1-certified lenses

This standard is especially relevant for:

• Shooting glasses
• Worksite protective eyewear
• Outdoor tactical sunglasses

3. CE EN ISO 12312-1 (European Union)

All sunglasses sold in the EU and EEA countries must conform to the CE standard, specifically EN ISO 12312-1, which governs:

• Frame construction safety
• Resistance to deformation
• Biocompatibility and labeling

✅ Why PC meets the mark:

• PC is safe for skin contact (non-allergenic)
• Durable under pressure and UV exposure
• Compliant with REACH and RoHS (for heavy metal and toxin limits)

Eyewearglobo’s PC frames are CE-ready and can be batch-tested with EU declarations of conformity (DoC) available for bulk shipments.

4. Australia/New Zealand (AS/NZS 1067)

For sports sunglasses exported to Australia and New Zealand, the AS/NZS 1067 standard applies. It includes requirements for both lenses and frame durability.

✅ PC is compatible with this regulation, particularly for:

• UV resistance
• Mechanical stress testing
• Visual distortion (related to lens-frame alignment)

5. Environmental and Recycling Compliance

As global regulations shift toward sustainability, material safety and recyclability also matter.

✅ PC is recyclable under many global waste management programs (Category #7 plastics), and:

• Complies with RoHS directives (no lead, mercury, cadmium, etc.)
• Can be produced using BPA-free PC resins (on request)
• Compatible with eco-focused marketing claims when sourced responsibly

🌍 This can be a selling point for brands targeting eco-conscious consumers or retailers with green certification criteria.

📦 Required Documentation for Buyers

At Eyewearglobo, we offer all necessary documentation for B2B buyers using PC frames:

This ensures smooth customs clearance, lower regulatory risks, and peace of mind for distributors and retailers.

⚠️ Buyer Tip:

Not all PC materials are created equal. Low-grade PC blends may not pass impact or UV resistance testing. Always confirm:

• Material purity
• Resin source
• Tested batch samples

With Eyewearglobo, we use certified PC materials from trusted suppliers and conduct pre-shipment testing for custom production.

China’s Manufacturing Advantages for PC Sunglass Frames

For global eyewear buyers—especially those seeking OEM or private-label production—China remains the most capable and cost-efficient source for polycarbonate (PC) sports sunglass frames. With decades of accumulated tooling experience, supply chain integration, and surface treatment expertise, Chinese manufacturers offer significant advantages in both speed and scale.

At the forefront of this production ecosystem is Eyewearbeyond, a trusted supplier with 5 advanced production lines and a global clientele.

Let’s explore why sourcing PC sunglass frames from China (and specifically from Eyewearbeyond) makes solid business sense.

1. Full-Chain Vertical Integration

Top-tier factories like Eyewearglobo offer everything under one roof:

This minimizes outsourcing, reducing cost, errors, and lead time—critical for wholesale and bulk buyers who value efficiency and control.

2. Competitive Pricing Without Sacrificing Quality

Thanks to:

• Domestic sourcing of high-grade PC granules
• Economies of scale in tooling and coatings
• High machine utilization rates

Eyewearglobo can offer factory-direct pricing that is:

• 20–30% more cost-effective than smaller factories
• Consistently below TR90 or nylon-based equivalents
• Flexible enough to support small-MOQ trial orders and bulk reorders

💬 Client insight:
A US-based client reduced their per-unit cost by 28% by switching their mid-range sports line to PC frames from Eyewearglobo—without losing any functional features.

3. Faster Turnaround Time for New Projects

China’s matured eyewear tooling industry enables:

• Mold creation in 10–15 working days
• Sample delivery within 7 days after mold test
• Bulk production ready in 30–40 days

Eyewearglobo enhances this with:

• 24/7 communication support
• Dedicated project managers for each B2B account
• Real-time tracking of production phases

⏱️ For seasonal or promotional product lines, this speed-to-market can mean the difference between hitting or missing sales windows.

4. Strong Track Record with Global Clients

Eyewearbeyond has successfully served:

• Eyewear wholesalers in the USA, UK, Brazil, South Africa, and Germany
• Independent brands focused on cycling, tactical, or outdoor collections
• Promotional marketing agencies seeking custom sports frames for events

We understand:

• Export documentation for different markets
• Labeling and packaging standards for retailers
• Logistics coordination via sea, air, or hybrid shipping

5. Flexibility for Private Label Brands

PC is especially suitable for brands wanting differentiation without high development costs. At Eyewearbeyond, you can:

• Create custom molds or modify existing ones
• Choose any Pantone frame color
• Apply brand logos, slogans, or slogans via printing or engraving
• Request limited-edition coatings (e.g., carbon fiber print, dual-tone)

Whether you’re launching your first eyewear SKU or managing a full catalog of activewear frames, our team can adapt to your design and branding needs.

6. Quality Assurance You Can Rely On

We understand how quality lapses—especially with frame materials—can harm your reputation and revenue. That’s why we apply:

• 3-step QC inspections (material, molding, finished product)
• FDA & CE spot testing on every batch
• Drop-ball and stress tests on request
• Transparent reporting before shipment

🔍 Trust is critical, especially for first-time buyers. Eyewearglobo provides full visual production updates, shipping samples, and multilingual customer support.

Conclusion: Is PC the Right Material for Your Next Sports Sunglass Frame Project?

Polycarbonate (PC) has proven itself as one of the most versatile, cost-effective, and performance-ready materials in the world of sports sunglass frames. From its high impact resistance and lightweight comfort, to its precise moldability and compatibility with custom finishes, PC meets the demands of both active end-users and savvy brand developers.

For manufacturers, PC simplifies the production process with:

• Shorter cycle times
• Lower defect rates
• Excellent surface finish options

For B2B buyers, PC offers:

• Strong margin potential
• Rapid prototyping and market testing
• Smooth regulatory compliance across key markets (FDA, CE, ANSI)

Whether you’re launching a mid-range sports line, developing your first custom frame, or expanding a collection of active outdoor eyewear, PC is a smart material choice that helps balance functionality, flexibility, and profitability.

📩 Ready to Start Your PC Sports Frame Project?