Kydex® & Boltaron® Thermoforming Sheets

Kydex® and Boltaron® are brand names for lines of durable, machinable thermoplastic sheets designed for forming and fabricating high-performance parts. Typically made from an acrylic/PVC blend, both materials can be drilled, vacuum formed, brake formed, drape formed, or punch pressed using standard tools, and can be molded to fit a wide range of shapes.

Both materials offer excellent impact strength and chemical resistance, making them suitable for housings, enclosures, and protective panels. They are easy to clean, resisting stains, scuffs, and graffiti while maintaining surface appearance. Fire-rated grades are available, including UL94 V-0 options.

Common applications include aviation and transit interiors, medical equipment, building interiors, fixtures, and furniture components. Kydex® and Boltaron® are also popular for thermoformed gun holsters and knife sheaths, as well as at-home forming projects.

• Rigid thermoforming materials with strong structural integrity
• Available in multiple gauges
• Distinctive textures and finishes available
• Wide range of colors offered
• Cost-effective
• Suitable for pressure forming
• Fire-rated options available

[Kydex® Spec Sheet PDF]

[Boltaron® Spec Sheet PDF]

Both Boltaron® and Kydex® are used across similar applications where durability, cleanability, and formability are required. Boltaron® offers complementary performance characteristics and is often selected alongside Kydex® for projects that demand consistent forming, a wide range of surface options, or specific durability requirements. Though they are often functionally interchangeable, various grades of Boltaron and Kydex will have differing properties that may make one more preferred for an application than the other. Before choosing a material, compare datasheets of the specific grades of Boltaron® or Kydex® to select one that will meet application requirements.

Bending and Forming:

Kydex® and Boltaron® sheets can be cut by scoring and snapping or by using standard shop tools. To bend or form either material, heat the sheet until pliable. Heat guns and toaster ovens are popular heating options for DIY or small projects. Microwaves will not work due to the low moisture content in the material.

Kydex® typically forms between 330°F and 385°F depending on thickness, and Boltaron® forms within a similar temperature range. Heat should be applied evenly to avoid overheating the surface. Thicker gauges require slightly higher forming temperatures.

Once heated, the material can be pressed over a mold or around an object using a press, clamps, or weighted fixtures. Allow the formed part to cool completely before handling or finishing.

Vacuum Molding Process:

Kydex® and Boltaron® sheets respond very well to vacuum forming and are commonly shaped using this process for holsters, sheaths, housings, trays, and interior components. When heated to their forming range, both materials become pliable and conform cleanly to molds with consistent surface retention. Once the heated Kydex® or Boltaron® sheet is placed over the mold, vacuum pressure draws the softened material tightly around the shape, producing crisp definition and uniform detail.

For best results, ensure the sheet is heated evenly before forming. After the vacuum pulls the material into place, allow the part to remain under vacuum until it cools and fully hardens. This helps maintain dimensional stability and ensures a clean, accurate finished form.

Boltaron® and Kydex® applications include:

• Gun holsters and knife sheaths
• Thermoformed housings and equipment enclosures
• Flat laminated panels
• Kick plates and push plates
• Exhibits and kiosks
• Aircraft, bus, automotive, and train interior parts
• Membrane-pressed components
• Workstations and fixtures
• Furniture components

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