Re: polycarbonate window thickness?
Acrylic is harder therefore less capable of taking an impact than polycarbonate. Poly is softer, so it flexes under load and impact. Since they are both petroleum based, they are stupid expensive. 3/8 or 1/2 would probably be cost prohibitive. Working with it can be done with anything that will cut. But use a table saw with a fresh fine toothed carbide blade for best results. A router works fine but tends to heat up and fuse the scraps. If you drill, clamp a scrap of wood to the back and use a drill press if possible. The drill will probably pull and want to blow out the back. Sand the holes smooth. The scratches in the hole are what we engineering geeks call stress risers. Cracks will propagate out from them, given the chance. Some folks hit the holes with a torch to melt and fuse the scratches. I did that on the edges of mine. What size peice are you looking for?