A White Paper for Design Engineers, OEMs, and Technical Specifiers
Abstract
From aircraft interiors to medical equipment housings and branded retail environments, KYDEX® thermoplastic sheet materials are engineered to perform under pressure—literally and figuratively. With a unique balance of impact resistance, formability, chemical resilience, and fire compliance, KYDEX® products meet the demands of today’s most regulated and performance-driven industries. This white paper outlines how KYDEX® is applied across key sectors, what performance requirements are met, and which grades are best suited for specific end-use environments.
1. Introduction: Beyond Generic Plastics
KYDEX® is not a single material but a diverse family of thermoplastic sheets designed for highly specific application needs. Its reputation for formability and toughness is well established, but what truly differentiates it is its ability to meet the compliance, safety, and durability standards of multiple high-stakes industries—all while maintaining design flexibility and visual appeal.
Each industry presents its own set of challenges—be it fire and smoke regulations, chemical resistance, frequent handling, or high mechanical loads. KYDEX® responds to these challenges with a range of grades and surface finishes, engineered for environments where traditional laminates, FRPs, or commodity plastics fall short.
2. Aerospace and Aviation Interiors
Application Needs:
- Flame and smoke compliance (FAR 25.853)
- Lightweight and thin-wall performance
- High cosmetic and tactile standards
- UV resistance and long-term dimensional stability
Typical Components:
- Tray tables
- PSU panels and bezels
- Window reveals and sidewalls
- Bulkheads and ceiling panels
Recommended Grades:
- KYDEX® 100: General-purpose aviation interior grade with high impact resistance and V-0 flammability rating.
- KYDEX® 5555 / 6565: Enhanced FST (Flame, Smoke, Toxicity) performance for international compliance and critical cabin locations.
Why It Works:
KYDEX® forms tight, thin-walled geometries with minimal shrinkage. Integrally colored sheets eliminate the need for painting or secondary coatings, reducing weight and eliminating VOCs.
3. Rail and Mass Transit Systems
Application Needs:
- Low flame, smoke, and toxicity (ASTM E-162/E-662)
- Impact resistance under vibration and high use
- Anti-graffiti and cleanability
- Long service life with minimal maintenance
Typical Components:
- Train interior panels
- Passenger partitions
- Seat shells and backers
- Fare collection enclosures
Recommended Grades:
- KYDEX® 6200 LTR / LTA: Rail-certified materials with FRA-compliant FST performance.
- KYDEX® 6565: High rigidity for large panel structures with excellent cleanability.
Why It Works:
KYDEX® resists mechanical fatigue and abrasion better than HPL or painted FRP panels, while supporting graphics and surface customization for branded transit interiors.
4. Healthcare, Laboratory, and Cleanroom
Application Needs:
- Disinfectant resistance
- Seamless edge and corner fabrication
- ISO 14644 cleanroom compatibility
- Biocompatibility (indirect) and ease of sanitation
Typical Components:
- Diagnostic equipment enclosures
- Mobile carts and workstations
- Wall protection systems
- OR cabinetry and pass-through panels
Recommended Grades:
- KYDEX® 115: ISO cleanroom-compatible, resists common healthcare cleaners.
- KYDEX® 160: Formulated for high-cleanability and surface hygiene applications.
Why It Works:
KYDEX® can be membrane pressed or post-formed to eliminate seams and sharp edges—essential for infection control. It resists discoloration and softening under repeated chemical exposure.
5. Retail Fixtures and Commercial Interiors
Application Needs:
- High durability in customer-facing environments
- Surface customization (woodgrain, color, texture)
- Miter folding and seamless corners
- Rapid fabrication and customization
Typical Components:
- Point-of-sale terminals
- Check-out counters and kiosks
- Display panels and cabinets
- Branded surfaces and signage
Recommended Grades:
- KYDEX® 152 WG (Woodgrain Series): Wood appearance with impact resistance and no risk of delamination.
- KYDEX® 200 Series: Smooth or textured finishes for branded interiors.
Why It Works:
KYDEX® performs better than HPL in edge durability and shock absorption, while allowing for CNC machining, heat folding, and fast prototyping with brand-consistent finishes.
6. Architecture, Institutional, and Public Infrastructure
Application Needs:
- Flame spread and smoke safety (ASTM E-84 Class A)
- Graffiti resistance and public vandal durability
- Seamless large-surface integration
- Field-modifiable for retrofit or adaptive reuse
Typical Components:
- Wall and corner guards
- Acoustic panels and partitions
- Restroom enclosures and public kiosks
- Elevator interiors and door panels
Recommended Grades:
- KYDEX® HD and 6185: High rigidity and surface hardness, ideal for high-use architectural elements.
Why It Works:
KYDEX® combines fire safety with long-term durability and repairability. Material consistency across production batches supports modular design and scalable deployment in large facilities.
7. Industrial and Technical Equipment
Application Needs:
- High structural stiffness
- Resistance to oils, coolants, and acids
- Ability to CNC and assemble without cracking
- Durable under vibration and mechanical load
Typical Components:
- Control housings and dashboards
- Testing device shells
- Mobile lab systems
- Water-resistant consoles
Recommended Grades:
- KYDEX® 130 and 6185: High heat deflection and tensile strength for dimensional control.
- KYDEX® HD: Thick-gauge variant with improved rigidity.
Why It Works:
KYDEX® retains tolerances during and after forming, supports post-machining, and handles thermal cycling better than many other industrial plastics.
8. Specialized and Emerging Applications
- Medical robotics: Seamless housings that resist motion wear and surface degradation
- Autonomous vehicle interiors: Lightweighting with flame resistance and design adaptability
- Education and STEM environments: Impact-proof panels for high-use lab furniture and walls
- Digital signage enclosures: UV-resistant and easy-to-brand with digital overlays
Conclusion
The breadth of KYDEX® applications across regulated and demanding sectors is a result of its exceptional material engineering and adaptability. From performance requirements to surface aesthetics, KYDEX® delivers reliable and compliant solutions for designers seeking long-term function with manufacturing flexibility.
Whether deployed as a structural panel, decorative enclosure, or cleanable medical surface, KYDEX® excels where conventional plastics and laminates fail.
Need Help Specifying KYDEX® for Your Industry?
Whether you’re designing a new product or retrofitting a critical system, RapidMade offers engineering-driven KYDEX® fabrication—from material selection to thermoforming, CNC finishing, and branded presentation.
Get started today at RapidMade.com or email info@rapidmade.com.
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