A Comprehensive Technical Guide to KYDEX® Sheet Solutions

A White Paper for Engineers, Designers, and Materials Specialists

Executive Summary

KYDEX® thermoplastic sheet materials have evolved into a multidimensional engineering solution for modern manufacturing demands. Originally developed for aerospace interiors, KYDEX® now supports mission-critical applications in medical environments, transportation infrastructure, retail systems, architectural surfaces, and industrial fabrication. This white paper presents a comprehensive review of KYDEX®’s capabilities—material properties, fabrication methods, application-specific grades, mechanical profiles, and compliance standards—to inform engineers and designers responsible for specifying and implementing advanced thermoplastic solutions.

1. Introduction: From Aerospace to Everywhere

Since its invention in 1965, KYDEX® has transitioned from a single fire-rated aviation-grade plastic into a family of thermoplastic sheets engineered to serve an array of demanding applications. Offering high impact resistance, flame retardancy, chemical stability, and aesthetic versatility, KYDEX® exemplifies the convergence of material science, manufacturing flexibility, and end-use performance. In today’s design-for-manufacture environment, it answers the growing demand for materials that can adapt to low-volume customization, stringent regulatory compliance, and end-user aesthetics—all while reducing processing costs.

2. Material Composition and Performance Attributes

KYDEX® is not a single formulation, but a family of extruded thermoplastic sheet alloys designed to meet a wide range of mechanical, thermal, chemical, and regulatory demands. Its base composition—a proprietary blend of polyvinyl chloride (PVC) and acrylic polymers—delivers a unique combination of toughness, formability, and surface aesthetics that make it a preferred alternative to traditional polymers such as ABS, HIPS, or polycarbonate in many industrial applications.

2.1 Polymer Synergy: PVC + Acrylic Alloy Behavior

The dual-polymer architecture of KYDEX® allows it to inherit advantageous properties from both resin types:

From PVC: Flame resistance, chemical durability, dimensional stability, and low thermal conductivity.
From Acrylic: Enhanced surface hardness, UV resistance, color retention, and thermoformability.

The result is a sheet material that not only meets technical performance requirements across structural and cosmetic roles but also processes reliably using a wide range of forming and fabrication methods.

This alloy system supports a broad spectrum of grades—each tuned for a specific property envelope (e.g., higher heat resistance, reduced smoke emission, increased impact toughness, or improved machinability).

2.2 Core Engineering Properties and Practical Significance

Impact Resistance

KYDEX® offers outstanding toughness, particularly in grades like KYDEX® 100 and 150, where notched Izod impact ratings reach 961 J/m. This characteristic reduces the risk of cracking or failure in thin-wall or deep-draw applications. It also increases survivability in environments subject to mechanical shock, such as transit interiors or high-traffic commercial kiosks.

Dimensional Stability

The material maintains structural integrity across variable humidity and temperature conditions. KYDEX® exhibits minimal warpage after forming, low shrinkage post-cooling, and excellent hot tear strength—essential for high-precision applications like instrument enclosures or load-bearing wall systems.

Thermal Resistance

Heat deflection temperatures range from 71°C to 91°C across grades. While not suited for continuous high-heat applications, KYDEX® performs reliably in elevated ambient temperatures, enclosed installations, and intermittent heat exposure, such as in lighting housings or electronic kiosks.

Fire Performance

A distinguishing advantage of KYDEX® is its broad fire compliance. Many grades meet:

UL 94 V-0: Self-extinguishing behavior without dripping
FAR 25.853 (a/d): Required for aircraft interiors
ASTM E-84 Class I/A: Used in architectural fire-rated panels
ASTM E-162/E-662: Required for mass transit applications

Its non-halogenated fire-retardant chemistry supports smoke suppression without compromising toughness.

Chemical Resistance

KYDEX® resists surface and structural degradation when exposed to:

Acids and bases (e.g., hydrochloric acid, sodium hydroxide)
Alcohols (e.g., ethanol, isopropanol)
Solvents (e.g., acetone, MEK)
Industrial fluids (e.g., oils, degreasers, disinfectants)

This makes it a viable material for chemically intensive environments like labs, hospitals, and food processing plants.

Surface Durability and Cleanability

Grades with Rockwell hardness up to R108 withstand repeated abrasion, cleaning cycles, and incidental impact. Stains—including graffiti, ink, and paint—can be removed without affecting gloss, texture, or color integrity. This property is essential in public-facing infrastructure, healthcare facilities, and transportation interiors.

2.3 Comparison to Conventional Materials

Property	KYDEX®	ABS	HPL (High-Pressure Laminate)	Polycarbonate
Impact Resistance	High (up to 961 J/m)	Moderate	Low	Very high
Fire Resistance	UL 94 V-0 / FAR Rated	UL 94 HB / V-2	Limited	Requires additives
Chemical Resistance	Excellent	Moderate	Poor to moderate	Good
Thermoformability	Excellent	Good	Not formable	Limited without stress
Surface Cleanability	High	Moderate	Low	Moderate
Cost (relative)	Medium	Low	Medium–High	High

This comparative analysis shows KYDEX® as a high-performance material occupying the middle ground between the cost-efficiency of ABS and the strength of polycarbonate—while offering enhanced aesthetic and fabrication advantages.

2.4 Aesthetic Engineering: Texture, Color, and Finish

KYDEX® sheets are available in a range of surface finishes—matte, gloss, embossed, metallic, carbon weave, granite, and realistic woodgrain. These finishes are integrally formed, not topcoated, ensuring long-term durability and colorfastness.

Integral Coloring: Eliminates chipping and scratching associated with painted or laminated surfaces.
Consistency: Matched sheet-to-sheet color and gloss for large panel systems or batch runs.
Visual Branding: Supports precise color-matching (Pantone, RAL) and textured branding without secondary decoration.

This visual and tactile flexibility allows KYDEX® to satisfy both performance and design requirements in sectors where appearance and durability must coexist—such as branded retail environments or executive-class transport interiors.

2.5 Material Stability Across Forming and Use Cycles

Engineered for thermal processing, KYDEX® exhibits high stability across repeated heating, cooling, and secondary forming cycles. This allows for:

Post-form corrections using localized heat and brake forming
Rework and retrofitting on-site without loss of surface integrity
High-yield forming with reduced scrap and tooling wear

Low reject rates and repeatable formability reduce total cost of ownership for manufacturers running short and medium production volumes.

3. Industry Applications and Sector-Specific Use Cases

The application scope of KYDEX® thermoplastic sheet materials extends across multiple regulated and performance-critical industries. Their adoption is driven not only by mechanical strength or thermal stability, but also by the ability to meet sector-specific codes, aesthetic expectations, and manufacturing constraints.

In this section, we explore how engineers, architects, and manufacturers apply different KYDEX® grades to solve challenges unique to each domain.

3.1 Aerospace and Aviation Interiors

Challenges Addressed: Flame retardancy, impact resistance, lightweighting, regulatory compliance (FAR 25.853), surface durability.

Application Roles:

Passenger Service Units (PSUs)
Tray tables and seat shells
Sidewall panels and bulkheads
Window reveals and overhead bins

Relevant Grades:

KYDEX® 100: General-purpose aerospace interior material; meets FAR 25.853 (a & d), high impact and wear resistance.
KYDEX® 5555 & 6565: Enhanced FST performance with low-smoke and low-toxicity emissions, suitable for next-gen cabin designs.

Design and Manufacturing Considerations:
KYDEX® allows for tight-tolerance forming with minimal shrinkage—crucial for large panels and modular interior systems. The material’s color-through pigmentation eliminates the need for painting, reducing VOC emissions and labor time.

3.2 Mass Transit and Rail Systems

Challenges Addressed: FST compliance (ASTM E-162/E-662), long-life durability, graffiti resistance, passenger safety.

Application Roles:

Interior cladding and wall panels
Window shrouds and seat backs
Train ceiling panels and duct covers
Fare collection kiosks and consoles

Relevant Grades:

KYDEX® 6200 LTR/LTA: Developed for U.S. and European rail markets; meets stringent FTA/FRA requirements.
KYDEX® 6565 FR: Improved flame, smoke, and toxicity ratings with better formability for complex contours.

Operational Benefits:
Thermoplastic durability ensures panels do not crack, chip, or delaminate under vibration or mechanical stress. Anti-graffiti finishes extend service intervals and lower lifetime maintenance costs.

3.3 Healthcare and Biotech Environments

Challenges Addressed: Chemical exposure, infection control, cleanability, ISO-class cleanroom compatibility.

Application Roles:

Surgical equipment housings
IV pump stations and mobile carts
Wall protection panels in ORs and ICUs
Lab cabinetry and workstations

Relevant Grades:

KYDEX® 115: Designed for frequent disinfection and Class I/A applications.
KYDEX® 160: For surgical-grade performance with added antimicrobial additives.

Clinical Engineering Insights:
Unlike laminated surfaces that harbor bacterial growth in seams or exposed edges, KYDEX® provides seamless, edge-wrap capability and weldable joints. It withstands hydrogen peroxide, bleach, quats, and phenolic disinfectants with no surface degradation.

3.4 Retail Fixtures, Displays, and Brand Interiors

Challenges Addressed: Aesthetic longevity, high traffic wear, miter folding for seamless edges, cost-efficient production.

Application Roles:

Point-of-sale (POS) enclosures
Self-checkout kiosks
Store fixture panels and display furniture
Branded wrap cabinetry

Relevant Grades:

KYDEX® WG (Woodgrain Series): Visual realism with superior durability over laminate or veneer.
KYDEX® 152 and 200 series: High rigidity and color-matched interiors for product-specific branding.

Fabrication Techniques:
KYDEX® supports CNC machining, heat-assisted bending, and miter-folding without delaminating. This allows for low-cost fabrication of fixtures that are resistant to chips, edge wear, and cleaning solvents—ideal for quick-service environments.

3.5 Architectural, Institutional, and Public Infrastructure

Challenges Addressed: Fire safety (ASTM E-84 Class A), vandalism resistance, design consistency, environmental hygiene.

Application Roles:

Wall protection in hospitals, schools, and labs
Acoustic panel facings and privacy partitions
Door skins and elevator interiors
Utility housings in public buildings

Relevant Grades:

KYDEX® 6200: Flame-rated, matte finish for institutional interiors.
KYDEX® HD: Higher rigidity for large-format panels and door assemblies.

Material Strategy:
Designers can specify integral color and finish for visual consistency throughout large building programs. KYDEX® is field-modifiable, allowing installers to heat-bend, cut, or form sheets for precise fitting without sending materials offsite.

3.6 Industrial and Technical Equipment Enclosures

Challenges Addressed: Chemical exposure, impact loading, serviceability, dimensional tolerance under thermal cycling.

Application Roles:

Diagnostic testing housings
Process control panels
Washdown-area enclosures
Mobile data consoles

Relevant Grades:

KYDEX® T, 130, and 6185: Higher heat and impact thresholds with customizable color and surface finish.

Manufacturing Advantages:
These KYDEX® grades withstand mechanical loading, retain cosmetic integrity in harsh conditions, and can be post-formed or fastened in modular systems. CNC-routing and snap-fit features allow for quick assembly and disassembly in field service scenarios.

3.7 Specialized Applications and Emerging Use Cases

Kiosks and interactive displays: Custom curved enclosures that demand formability and surface protection.
Autonomous vehicle interiors: Lightweight, high-strength panels with aesthetic control.
Medical robotics: Impact-resistant, disinfectant-tolerant panels that withstand repeated mechanical motion.
Educational STEM furniture: Durable, high-touch materials in collaborative labs and classrooms.

4. Manufacturing Processes and Design Flexibility

KYDEX® sheet materials are engineered for compatibility with diverse forming and fabrication methods, enabling manufacturers to transition seamlessly between short-run prototyping, mid-volume production, and full-scale industrial applications. Unlike laminates or rigid plastics that require narrow forming tolerances or extensive secondary finishing, KYDEX® supports precise, repeatable processing through both traditional and advanced manufacturing workflows.

This section outlines the primary fabrication processes suitable for KYDEX®, including forming, bonding, machining, and post-processing techniques.

4.1 Thermoforming (Vacuum and Pressure Forming)

KYDEX® is specifically engineered for vacuum and pressure forming—making it the preferred material for 3D surface geometries and complex enclosures.

Vacuum Forming

Suitable for medium-to-low detail geometries
Lower tooling cost, ideal for prototypes and low-volume production
Works best with radiused edges, shallow draw depths, and symmetrical parts

Pressure Forming

Offers finer definition and tighter tolerances than vacuum forming
Enables sharp corners, deep undercuts, and complex compound surfaces
Ideal for highly detailed medical housings, kiosk enclosures, and vehicle interiors

Forming Temperature Range: 160–205°C (320–400°F)
Draw Ratio Tolerance: 3:1–5:1 depending on grade
Wall Thickness Retention: Maintains 75–90% of original sheet gauge

Engineering Notes:

Formed parts exhibit excellent recovery and low spring-back
Suitable for CNC trimming post-forming
Integrally colored surface eliminates post-painting

4.2 Membrane and Bladder Pressing

Membrane pressing involves wrapping KYDEX® sheets over contoured substrates using a heated elastic membrane under vacuum or pressure. This technique is optimal for furniture, cabinetry, and medical equipment components that require seamless visual finish and ergonomic curves.

Advantages:

Seamless wraps around complex 3D geometries
Eliminates need for mechanical fasteners or edge banding
Consistent surface adhesion, even on radiused or recessed profiles

Design Considerations:

Compatible with MDF, particleboard, phenolic, or foam cores
Supports full-surface bonding with heat-activated adhesives
Requires controlled heating and dwell timing to prevent surface marking

4.3 Laminating and Composite Panel Assembly

KYDEX® can be laminated to a variety of substrates, including aluminum honeycomb, MDF, plywood, and polymer cores, using either cold press or hot press methods. This makes it an ideal candidate for wall systems, panelized kiosks, architectural partitions, and vehicle interiors.

Hot Press Lamination:

Uses thermosetting or pressure-sensitive adhesives
Ensures uniform adhesion over large areas
Provides superior bond strength for vertical and high-load applications

Cold Press Lamination:

Lower equipment cost
Ideal for flat, low-load applications and prototyping
Suitable for rapid-turnaround retail displays and signage

Special Techniques – Miter Folding:

V-grooves are CNC-routed into laminated panels to allow folded 90° corners
No delamination or surface cracking at bends
Produces seamless edge joins without separate trim or cover pieces

4.4 Brake Forming and Post-Form Bending

KYDEX® can be formed post-fabrication using localized heating and a press brake or hand bending setup. This process enables last-minute customization, field adjustments, or retrofit modifications.

Brake Forming Capabilities:

Tight bends down to 1.5× sheet thickness radius
Wire-heating or strip heaters recommended for heat lines
Clean bends achievable without surface whitening or micro-cracking

Use Cases:

Edge returns and flanges
Corner stiffening on panels
On-site modification for enclosure fitment or HVAC components

4.5 CNC Machining and Secondary Processing

KYDEX® is fully compatible with standard machining operations, including:

Routing (2D and 3D)
Sawing (panel saws, table saws)
Drilling (twist bits, Forstner bits)
Milling (manual and CNC)
Die-cutting and shearing for thin-gauge stock

Machining Properties:

Does not chip or splinter like laminate
Dust is non-hazardous but should be extracted
Maintains tight tolerances post-trim (±0.25 mm typical)

KYDEX® also supports laser cutting on specific grades, particularly thin stock for detailed patterns, branding, and light-pass features.

4.6 Assembly Techniques and Fastening Methods

KYDEX® panels and parts can be assembled using various bonding and fastening techniques depending on application and industry standards.

Fastening:

Mechanical: Screws, rivets, clips, snap-fits
Chemical: Solvent bonding, epoxy adhesives, contact cements
Thermal: Heat staking and plastic welding (for select KYDEX® blends)

Edge Finishing Options:

Routed profiles with chamfer or radius
Wrapped corners via miter fold
Heat-formed hems for strength and safety

In cleanroom, medical, or food-service applications, edge welding and sealed joints provide a sanitary, waterproof, and durable finish.

4.7 Printing, Embossing, and Decoration

For applications where brand identity or graphical information is important, KYDEX® supports:

Silkscreen printing
Hot stamping
Laser engraving
Digital direct printing (on printable variants)

Embossed textures such as leather grain, stone, or brushed metal can be integrated during sheet extrusion, offering durable and permanent surface effects without topcoats or overlays.

5. Comparative Mechanical Properties

Material selection is ultimately driven by performance—quantified through standardized testing and evaluated in the context of an application’s structural, thermal, and environmental demands. KYDEX® thermoplastic sheets are engineered to offer high strength, exceptional impact resistance, and thermal and dimensional stability, with performance tailored across its product family to suit varying use cases from lightweight transit panels to chemically resistant medical equipment.

This section provides a detailed examination of KYDEX®’s key mechanical properties and contextualizes its performance against other commonly specified materials such as ABS, HIPS, polycarbonate, FRP, and high-pressure laminate (HPL).

5.1 Key Mechanical Properties of KYDEX® Grades

The table below summarizes standardized ASTM-tested performance values for select KYDEX® grades.

Property	KYDEX® 100	KYDEX® 107	KYDEX® 115	KYDEX® 130	KYDEX® 6185	KYDEX® HD
Notched Izod Impact (J/m)	961	212	267	187	267	33.9 N·m
Tensile Strength (MPa)	42	48	40	41	44	50
Tensile Modulus (MPa)	2340	2700	2070	2410	2350	2750
Elongation at Break (%)	10–15	12–18	10–12	12–14	10–13	9
Rockwell Hardness (Scale R)	94	108	107	101	104	114
Flexural Modulus (MPa)	2100–2300	2600	2100	2300	2250	2800
Heat Deflection Temp @ 1.8 MPa (°C)	78.3	78.3	81.1	76.7	90.6	75.1
Water Absorption (%)	<0.30	<0.25	<0.25	<0.30	<0.20	<0.30
Flammability Rating (UL 94)	V-0	V-0	V-0	V-0	V-0	V-0

Note: Mechanical values are tested per ASTM D256 (impact), ASTM D638 (tensile), ASTM D790 (flexural), and ASTM D648 (HDT). Data is for reference only and subject to processing conditions and sheet thickness.

5.2 Property-by-Property Engineering Analysis

Impact Strength (Notched Izod)

KYDEX® 100 offers some of the highest impact resistance in its class, comparable to polycarbonate and significantly higher than ABS or HIPS.
This makes it ideal for deep-draw thermoforming and high-risk environments (e.g., public transit, healthcare, kiosks).
Grades like KYDEX® 115 and 6185 maintain strong impact strength while improving chemical resistance or flammability.

Tensile and Flexural Modulus

Tensile strength values across KYDEX® grades range from 40–50 MPa, comparable to high-quality ABS or PVC blends.
Flexural modulus values above 2000 MPa ensure stiffness in structural applications such as wall panels and equipment housings.
KYDEX® HD exhibits the highest tensile and flexural modulus, supporting large-format installations and load-bearing designs.

Thermal Resistance

Most KYDEX® grades remain stable up to ~80°C under load, with 6185 offering elevated thermal performance (HDT ~90°C).
For short-term heat exposure and thermally regulated environments (e.g., electronics housings), these properties are more than adequate.

Dimensional and Environmental Stability

All KYDEX® grades show low water absorption (<0.30%), critical for applications in humid, wet, or sterilized environments.
Unlike hygroscopic materials like nylon or polycarbonate, KYDEX® does not require drying before forming and resists dimensional creep.

Surface Hardness

Rockwell hardness values as high as R114 support abrasion resistance in high-touch environments.
Surface finish remains intact under mechanical cleaning, minor impacts, or long-term use—essential for institutional and medical applications.

5.3 KYDEX® vs. Other Thermoplastics: Comparative Summary

Property	KYDEX®	ABS	Polycarbonate (PC)	FRP Laminate	HPL (Laminate)
Impact Resistance	Excellent	Moderate	Excellent	Good	Poor
Fire Resistance	V-0 (most grades)	V-2 or HB	V-0 (with additives)	Moderate–High	Moderate
Formability	Excellent	Good	Fair (stress-prone)	Poor	Not Formable
Chemical Resistance	Excellent	Moderate	Good	Good	Poor to Moderate
Edge Durability	High	Moderate	High	Low	Very Low
Surface Maintenance	Easy	Moderate	Moderate	Challenging	Poor
Recyclability	Yes	Yes	Yes	Limited	No
Tool Compatibility	Standard CNC	Standard CNC	Specialized/Sharp Tools	Limited	Limited

5.4 Thickness Range and Structural Considerations

KYDEX® sheets are available in gauges ranging from 0.71 mm (0.028″) to 12.7 mm (0.5″) depending on grade, color, and texture. This wide range supports:

Thin-gauge cladding for lamination or membrane press
Mid-thickness wall panels for load and impact resistance
Thick-section structural parts for equipment housings, vehicle interiors, and large molded components

Designers should select thicknesses based on intended draw depth, edge detail, structural load, and fastening technique.

5.5 Surface Texture, Color, and Optical Consistency

Beyond physical performance, KYDEX® materials are engineered for visual uniformity:

Gloss control from matte (6 GU) to semi-gloss (70+ GU)
Embossed patterns for grip, branding, or decorative effect
Color matching to RAL, Pantone, or brand-specific swatches
Low-light reflectivity available for tactical or control room use
Metallic and woodgrain overlays with integrated mar resistance

Consistent optical and textural appearance is critical for large-format, multi-panel installations in transportation, healthcare, and retail environments.

6. Regulatory Standards and Environmental Compliance

In today’s engineering and product development environments, material compliance is not optional—it is a core design requirement. Whether working in aerospace interiors, medical systems, public transportation, or commercial infrastructure, materials must meet stringent fire safety, health, and environmental regulations while supporting traceability and performance documentation.

KYDEX® thermoplastic sheets are developed to exceed the industry’s most demanding compliance benchmarks. Their chemical formulation, processing control, and documented performance support designers and OEMs in meeting global regulatory frameworks with confidence and consistency.

6.1 Fire Safety and Smoke Emission Compliance

One of KYDEX®’s defining features is its ability to meet advanced fire, smoke, and toxicity (FST) criteria across multiple industries and geographic regions.

Aviation (FAR 25.853)

Vertical burn and 60-second/12-second flammability testing
Heat release rate (per ASTM D3675, OSU calorimeter)
Smoke density and toxicity in line with FAA regulations

Grades such as KYDEX® 100, 5555, and 6565 are routinely used in aircraft interiors, meeting FAA Part 25 Appendix F criteria for occupied cabin surfaces.

Mass Transit (ASTM E-162 / E-662, NFPA 130)

KYDEX® 6200 and LTA/LTR series meet U.S. Federal Transit Administration (FTA) and Federal Railroad Administration (FRA) performance standards.
These grades satisfy requirements for:
- Surface flammability (ASTM E-162, Radiant Panel)
- Smoke generation (ASTM E-662, NBS chamber)
- Flame spread and optical density thresholds

Architectural and Building Materials

ASTM E-84 (Steiner Tunnel Test): KYDEX® grades achieve Class A classification for flame spread and smoke development.
Frequently used in wall cladding, partitions, and elevator interiors in schools, hospitals, and commercial buildings.