A Cost-Effective, High-Performance Alternative to KYDEX T
Executive Summary
In the thermoforming industry, material selection directly impacts cost, performance, and production efficiency. Boltaron® 4335, a high-impact, flame-resistant PVC sheet, emerges as a strong alternative to the widely used KYDEX® T, particularly in aerospace, electronics, and specialty equipment applications. Boltaron 4335 offers comparable mechanical and thermal performance, enhanced manufacturability, and significantly better procurement flexibility—making it an ideal material for agile manufacturing operations.
Material Overview
Boltaron® 4335 is a proprietary thermoplastic sheet engineered for durability, flame compliance, and formability. It is designed to perform under rigorous conditions while supporting cost-efficient production workflows.
Key Mechanical Properties:
- Tensile Strength: 6,000 psi (41 MPa)
- Flexural Strength: 9,200 psi (63 MPa)
- Flexural Modulus: 330,000 psi (2,275 MPa)
- Izod Impact Resistance: 18 ft-lb/in (953 J/m)
- Hardness: Rockwell R110
Flame and Heat Performance:
- UL 94 V-0, 5VA Certified (as thin as 0.045 mm)
- FAR 25.853(a)(i) and (ii) Compliant
- Heat Deflection Temperature: 161°F (72°C) @ 264 psi
- Radiant Panel Index (ASTM E162): <10
Thermoforming Characteristics
Processing Range:
- Forming Temperature: 335–370°F (168–188°C)
- Mold Shrinkage: 0.5–0.7%
- Drying: Not required
The material is optimized for high-volume vacuum and pressure forming processes. Its stability under heat, combined with consistent shrinkage and no drying requirement, reduces cycle time and enhances part reproducibility.
Comparative Evaluation: Boltaron® 4335 vs. KYDEX® T
| Attribute | Boltaron® 4335 | KYDEX® T |
| MOQ | 500 lb | 600 lb |
| Lead Time | Shorter | Longer |
| Impact Resistance | 18 ft-lb/in | ~15 ft-lb/in |
| Forming Temp. | 335–370°F | 365–390°F |
| Pre-drying | Not required | Sometimes recommended |
| Flame Compliance | UL 94 V-0, 5VA; FAR 25.853 | Same |
| Flexural Modulus | 330,000 psi | ~320,000 psi |
KYDEX® T is known for performance but is often more expensive, with longer procurement cycles and higher MOQs. Boltaron 4335 delivers equivalent regulatory and mechanical properties with added supply chain advantages.
Design and Application Flexibility
Boltaron® 4335 is available in a wide range of gauges (0.028″ to 0.250″) and sheet sizes (up to 60″ x 120″). It supports a broad aesthetic portfolio with custom colors and textures, ideal for both utilitarian and visual applications.
Key Applications:
- Aircraft cabin panels and pet carriers
- Kiosk housings and information terminals
- Medical equipment shells
- Transportation and public display housings
- Ruggedized enclosures for sensitive electronics
Conclusion
Boltaron® 4335 delivers a unique combination of durability, flame compliance, and manufacturability—making it a superior alternative to KYDEX® T for many thermoforming needs. Its lower MOQ, faster availability, and ease of processing support streamlined production and cost-effective design flexibility.
Contact Us
Looking to optimize your next thermoforming project?
Partner with RapidMade for material consultation, prototyping, or custom fabrication with Boltaron® 4335.
Our engineering experts will help you reduce lead times, lower production costs, and meet exacting performance standards.
Visit RapidMade.com to get started.
