Let’s be real—picking a thermoplastic shouldn’t feel like spinning a wheel. However, when there are dozens of grades to choose from and a dozen more variables in play (flame rating, chemical resistance, formability, aesthetics, and tooling compatibility), it can feel overwhelming.
That’s where KYDEX® flips the script.
This isn’t just “a plastic.” KYDEX® is more like a material platform—with over 40 grades designed for specific real-world applications. Whether you’re building something that goes into a plane, a hospital, a subway car, or a showroom, there’s a version of KYDEX® that fits. The trick is knowing how to pick it—and that starts with asking the right questions.
Here’s how we break it down at RapidMade.
Step 1: What’s It Up Against?
Before you consider color, texture, or sheet thickness, start with the environment.
- Heat and flame? If it’s headed for an aircraft or transit system, look for KYDEX® 100, 5555, or 6565—all of which meet fire, smoke, and toxicity (FST) requirements like FAR 25.853 and ASTM E-662.
- Chemical exposure? For applications in healthcare, laboratories, or cleanrooms, KYDEX 115 and 160 resist harsh disinfectants and meet ISO 14644 standards.
- Vandalism or heavy abuse? Transit interiors, school equipment, or public kiosks benefit from tougher grades, such as KYDEX 6200 or HD.
- Moisture and wear? Think restrooms, marine, or field-deployed gear—water-resistant grades like KYDEX® HD shine here.
Match the material to the world it’s going to live in.
Step 2: What’s the Process?
KYDEX® behaves differently depending on how you’re forming or finishing it—and that’s one of its strengths.
- Vacuum forming? KYDEX 100 and 130 provide tight draws without thinning. Great for molded panels and enclosures.
- Pressure forming? KYDEX® 6185 has the fidelity you want for details and tight tolerances.
- Membrane pressing or flat bonding? KYDEX 152 and the WG Series (woodgrain) lay down beautifully over cores such as MDF.
- Miter folding? This is where KYDEX® shines. V-groove, heat, fold—done. KYDEX 130 and HD are ideal for this application.
- CNC machining? KYDEX HD machines clean, maintain a crisp edge, and resist chipping or flaking like brittle laminates.
Don’t fight your material—pick one that works with your existing tooling and workflow.
Step 3: Does It Meet Code?
If your part is used in a public or regulated space, you don’t want surprises at the approval stage. KYDEX® takes a lot of that guesswork out.
- Aviation? FAR 25.853 is a standard applicable to several grades.
- Transit? KYDEX® 6200 and 6565 meet all major North American fire and smoke rules.
- Cleanrooms? Look for ISO-compliant grades, such as 115 and 160.
- Sustainability or health? All major KYDEX grades are RoHS and REACH compliant, meeting low-VOC standards for LEED and WELL buildings.
Bonus: It’s all documented and batch-traceable, which helps when you’re chasing procurement specs or filing paperwork.
Step 4: How Does It Look and Feel?
This is where KYDEX® beats the competition. Unlike laminates or painted plastics, the color, gloss, and texture are baked into the sheet.
- Color-through? Yes. What you see is what you get.
- Custom gloss? Available in matte (6 GU) to semi-gloss finishes.
- Textures? Leather grain, carbon fiber, stone, brushed metal—it’s all extruded, not sprayed or coated.
- Branding? You can print, stamp, engrave, or hot-press your logo directly into the surface.
Whether you’re building a control panel or a customer-facing kiosk, KYDEX® keeps the visual clean and the finish durable.
Step 5: What’s It Costing You?
KYDEX may cost more per sheet than ABS or acrylic, but when you factor in the savings from fabrication, rejection, tooling, and lifecycle wear, it often comes out ahead.
- No painting = fewer VOCs and fewer steps
- No laminating = fewer failure points
- Less scrap = tighter tolerances, fewer rejects
- More durability = fewer replacements and call-backs
It’s not just about material cost—it’s about production cost and field reliability.
Wrap-Up: Material Selection Is an Engineering Decision
Choosing the right KYDEX® grade isn’t a cosmetic decision—it’s an engineering one. When you align the material with the process, the application, and the code environment, you make smarter parts. Parts that last. Parts that ship on time. Parts that don’t come back.
KYDEX® isn’t for everything. But when it fits, it fits like nothing else.
Need help selecting the right KYDEX for your project?
RapidMade offers full-service support for material selection, prototyping, thermoforming, machining, and production, built around your specs.
Start your project at rapidmade.com or email [email protected]
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