A Technical White Paper for Material Engineers and Product Developers
Abstract
KYDEX® thermoplastic sheet materials represent a class of engineered polymers combining toughness, thermal stability, chemical resistance, and manufacturability. This white paper provides a detailed evaluation of KYDEX®’s core material composition, mechanical properties, and thermal behavior. Through ASTM test data and comparative analysis, this guide equips engineers and designers with the technical insight needed to evaluate KYDEX® for structural, aesthetic, and regulatory-critical applications.
1. Introduction: A Platform of Thermoplastic Performance
KYDEX® sheets are extruded from proprietary blends of polyvinyl chloride (PVC) and acrylic polymers. This combination produces a material platform that outperforms conventional ABS, HIPS, and laminates in dimensional stability, fire resistance, and impact strength. The acrylic phase contributes gloss retention and formability, while the PVC matrix provides flame resistance and chemical durability.
With grades tuned for various environments—from aerospace interiors to clinical enclosures—KYDEX® offers mechanical consistency and regulatory performance in a format that is highly processable through thermoforming, routing, and laminating methods.
2. Material Properties and Engineering Performance
2.1 Polymer Alloy Synergy
The PVC-acrylic blend at the heart of KYDEX® formulations balances elasticity and rigidity, enabling formability without loss of strength. Properties such as elongation-at-break and modulus of elasticity vary across grades but consistently provide:
- Excellent resistance to cracking under thermal or mechanical load
- Uniform wall thickness after forming
- Resistance to common solvents and cleaners
2.2 Impact and Structural Strength
KYDEX® offers exceptional impact resistance, with notched Izod values up to 961 J/m (KYDEX® 100). This allows for use in high-contact environments like public transit interiors, mobile healthcare carts, and educational furniture.
Flexural and tensile modulus values in the range of 2000–2750 MPa provide structural stiffness appropriate for vertical installations, enclosures, and mid-span panel applications. Elongation at break values from 10–18% support deep-draw forming without splitting.
2.3 Thermal Behavior and Dimensional Stability
KYDEX® exhibits heat deflection temperatures (HDT) between 75–91°C, depending on grade and thickness. These properties support use in semi-enclosed environments exposed to heat from lighting, electronics, or HVAC systems. Dimensional stability under heat is critical for tight-fitting panels and enclosures that cannot tolerate warping or expansion.
Water absorption rates below 0.30% ensure long-term dimensional integrity in humid or frequently cleaned settings—essential for medical and transit environments.
3. Comparative Mechanical Property Table
| 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 (R Scale) | 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 |
Data are per ASTM D256 (impact), ASTM D638 (tensile), D790 (flexural), and D648 (HDT). Performance may vary with processing.
4. Comparison with Conventional Thermoplastics
| Performance Attribute | KYDEX® | ABS | Polycarbonate | FRP Laminate | HPL (Laminate) |
| Impact Resistance | Excellent | Moderate | Excellent | Good | Poor |
| Heat Resistance (HDT) | Good | Fair | High | Fair | Limited |
| Chemical Resistance | Excellent | Moderate | Good | Good | Poor |
| Formability | Excellent | Good | Fair (stress risk) | Poor | Not Formable |
| Cleanability/Disinfection | Excellent | Fair | Good | Poor | Poor |
| Flame Retardancy (UL 94) | V-0 | HB or V-2 | V-0 (additives) | V-0 | Class B or lower |
KYDEX® delivers a blend of durability, cleanability, and fire performance that exceeds most general-purpose plastics and laminate materials—especially in regulated environments.
5. Engineering Summary
KYDEX® delivers robust and balanced mechanical performance for structural and surface applications. Key technical advantages include:
- High impact resistance for damage-prone environments
- Thermal stability and low moisture uptake for dimensional consistency
- Cleanability and surface durability under mechanical and chemical stress
- Wide grade selection tuned for impact, rigidity, heat, and forming behavior
These properties, combined with integral color, gloss control, and industry-grade certifications, make KYDEX® a material platform of choice for sectors requiring form, function, and regulatory compliance in a single material system.
Partner With a KYDEX® Fabrication Expert
For engineers and fabricators seeking to translate material performance into real-world components, RapidMade offers end-to-end KYDEX® services—from material selection and DfM support to forming, machining, and finishing.
Ready to prototype or scale your KYDEX® application?
Visit RapidMade.com or contact [email protected] for a consultation.
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