Technical Brief

Ideal Conditions for Forming KYDEX® Sheet

TB - 140-C
Temperature • KYDEX® sheet forms differently than an ABS and Polycarbonate.
Profile for • KYDEX® sheet is denser than ABS and Polycarbonate, results in heating the material differently than ABS and PC.
Thermoforming • The recommended temperature profile for heating KYDEX® sheet is, normally achieved by setting the bottom heaters
higher then the top heaters.
KYDEX® Sheet
Products 1) The distance between the bottom heaters and the sheet is greater than the distance between the top heaters
and the sheet.
2) Running the bottom heaters higher in temperature allows the heat to rise and be trapped under the sheet,
allowing to be absorbed into the KYDEX® sheet faster, reducing the heating time.
3) Running the top heaters lower, reduces the amount of heat being applied to the sheet surface, hence, reducing
the gloss level of the part.

• A good starting temperature profile for forming KYDEX® sheet is:

• 30% top heaters and 70% bottom heaters.

• A good rule of thumb (starting point) on the dwell time (heating) for heating KYDEX® sheet is:
• For sheet thickness up to 0.125” -1 second per mil
(ex.: 0.125” = 125 seconds)
• For thicknesses over 0.125” - 1 ¼ seconds per mil
(ex.: 0.200” = 250 seconds)

• It is always good to run the perimeter of the ovens 5% to 10% higher than the rest of the settings (depending
on ambient temperature).
• Purpose for doing this, is to help compensate for any air flow across front of the oven.

Example of Top and Bottom Oven Settings for Ceramic, Quartz and Halogen Heaters:

Top Oven Bottom Oven

35% 35% 70% 70%

35% 30% 30% 30% 35% 70% 70% 70% 70% 70%

040% 30% 30% 30% 30% 30% 40% 75% 70% 70% 70% 70% 70% 75%
SEKISUI SPI
ISO 9001 and 14001 Certified
35% 30% 30% 30% 35% 75% 70% 70% 70% 75%
Customer Service
6685 Low St, Bloomsburg, PA 17815 USA
Phone: 800.325.3133, +1.570.389.5810
40% 40% 75% 75%
Outside the US: +1.570.389.5814
Fax: 800.452.0155, +1.570.387.7786 Front Front
Email: [email protected]

Technical Service
Phone: 800.682.8758
Fax: +1.570.387.8722
Outside the US: +1.570.387.6997
[email protected]

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 Technical Brief

Ideal Conditions for Forming KYDEX® Sheet

TB - 140-C
Thermoforming Example of Top Oven Settings for Gas Catalytic Heaters:
and Mold Top Oven Bottom Oven
Shrinkage
1.2 1.2 2.0 2.0

1.2 1.0 1.0 1.0 1.2 2.0 2.0 2.0 2.0 2.0

1.5 1.0 1.0 1.0 1.0 1.0 1.5 2.1 2.0 2.0 2.0 2.0 2.0 2.1

1.2 1.2 1.2 1.2 1.2 2.1 2.0 2.0 2.0 2.1

1.5 1.5 2.1 2.1

Front Front

Gas Catalytic Heats operate on CWI (Column of Water Inches)

Important Thermoforming Molds:

Thermoforming
Information Male Molds Female Molds
Min. draft angle: 2 - 4º Min. draft angle: 1 – 2º
Min. radius: 2.30mm (0.094”) Min. radius: 1.60mm (0.063”)
Mold shrinkage: 0.40 – 0.60% Mold shrinkage: 0.50% – 0.70%

Pressure Forming - Female Molds

Min. draft angle 1 - 2°
Min. radius 1.6mm (0.063”)
Mold Shrinkage: 0.40% - 0.50%

Drying of KYDEX® Sheet:

KYDEX® sheet is less hygroscopic then most thermoplastics and does not require drying. But, if the material has been
stored for a period of time in a humid environment, drying may need to be performed.

Recommended Drying Temperatures and Times:

(at 68ºC (155ºF) in an air-circulated oven)
SEKISUI SPI
ISO 9001 and 14001 Certified Sheet Thickness Minimum Time (hrs)
Customer Service 2.00mm (0.080”) 10
6685 Low St, Bloomsburg, PA 17815 USA 3.20mm (0.125”) 16
Phone: 800.325.3133, +1.570.389.5810
Outside the US: +1.570.389.5814
6.40mm (0.250”) 24
Fax: 800.452.0155, +1.570.387.7786
Email: [email protected]

Technical Service
Phone: 800.682.8758
Fax: +1.570.387.8722
Outside the US: +1.570.387.6997
[email protected]

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© 2014 Sekisui Polymer Innovations, LLC. All rights reserved. KYDEX is a registered trademark of Sekisui Polymer Innovations, LLC. | 091614
 Technical Brief

Ideal Conditions for Forming KYDEX® Sheet

TB - 140-C
Thermoforming Forming Surface Temperatures Guidelines:
Temperature
Guidelines • Sheet should not exceed 400°F (204°C).
• 165 - 177°C( 330 - 350°F ) for 0.71mm - 1.50mm (0.028” to 0.060”).
• 182 - 196°C (360 - 385°F) for 1.50mm - 3.20mm (0.060” to 0.125”).
• 196 - 204°C (385 - 400°F) for 3.20mm and greater (0.125” and greater).
• The recommended temperature ranges are to give you the optima temperature of the KYDEX sheet to achieve good
detail and uniform wall thickness.
• To avoid warpage and/or distortion in the formed part, allow the surface temperature of the part to cool below
65.5ºC (150ºF) before removing the part from the mold.
• If you are using a temperature controlled mold, maintain a mold temperature of 65.5ºC (150ºF) in the cooling cycle
• Do Not exceed 71.1ºC (160ºF). This is close to the HDT (Heat Deflection Temperature) of the material.
Forming KYDEX® sheet does not contain any plasticizers, brominated fire retardants, or heavy metal stabilizers, including lead
Technique for and cadmium.
KYDEX® Sheet
Plasticizers:
Plasticizers are used as softening agents and provide low temperature flexibility and weldability.

Flame Retardants:
Brominated Flame Retardants: PentaBDE, OctaBDE, and DecaBDE are brominated flame retardants typically used in
thermoplastics such as ABS, Polyethylene, Polyurethane, or Polystyrene to help comply with the stringent UL 94 fire
standard. KYDEX® sheet has inherent flame retardant properties so no flame retardant additives are necessary to
comply with such a standard.

Stabilizers:
Most stabilizers are used in rigid vinyl applications such as construction products thanks to their processability and
durability. Lead and cadmium-based stabilizers are used principally in vinyl wire and cable insulation. KYDEX® sheet
does not contain any lead or cadmium.

Note: Using FR/ABS or ABS temperature profiles, which are more of an even top and bottom temperature profile
(50/50, 60/60, etc), KYDEX sheet would very likely be formed with a glossy primary surface, due to the more
concentrated heat on top. By using the recommended temperature profile above, the heating cycle times will be
comparable to FR/ABS and other thermoplastics.
SEKISUI SPI
ISO 9001 and 14001 Certified
By having a higher tear strength, KYDEX® sheet will not sag like FR/ABS, ABS and other thermoplastics. So, the use of
Customer Service a sag sensor would need to be adjusted to accommodate the difference in sag rate between KYDEX® sheet and other
6685 Low St, Bloomsburg, PA 17815 USA
Phone: 800.325.3133, +1.570.389.5810
thermoplastics.
Outside the US: +1.570.389.5814
Fax: 800.452.0155, +1.570.387.7786
Email: [email protected]
Due to constant changes in forming conditions, relating to ambient temperature changes, drafts on the shop floor, age
and condition of the equipment, you can not always rely on fixed cycle times.
Technical Service
Phone: 800.682.8758
Fax: +1.570.387.8722 Although there are ways of measuring surface temperature to achieve the proper forming temperature (Infrared
Outside the US: +1.570.387.6997
[email protected] temperature sensors, paper thermometers, etc.), the most difficult aspect is achieving the proper core temperature
as well. By achieving the proper core temperature, internal stresses in the material are reduced, improving part
sekisui-spi.com quality and consistency.

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 Technical Brief

Ideal Conditions for Forming KYDEX® Sheet

TB - 140-C
Forming Therefore, we suggest that you rely on visual methods as well in determining the correct time to form, rather than relying
Technique for strictly on cycle time.
KYDEX® Sheet
The method below relies on sheet appearance. Most likely, your operators are already using this method to some extent.
The method is a four-stage sequence that will tell the operator when the sheet is to come out of the oven and will signal
when to adjust the oven conditions. By using this four-step method you will achieve higher quality, get greater consistency
and have fewer rejects. The bottom line: This method saves you money.

Benefits of Using KYDEX® sheet:

KYDEX® Sheet • Is a monolithic sheet (colour throughout), where competitors are mostly capped product
• Exhibits higher impact resistance
• Is easy to thermoform
• Is a great material for pressure forming
• Allows downgrading, reducing cost and weight
• Has excellent extensibility in deep draw thermoformed parts
• Retains its pattern texture after thermoforming
• Provides very good uniform wall thickness in thermoformed parts
• Cycle times are similar in all products
• Produces less rejects in thermoforming due to its quality
• Has short lead times (usually 3 weeks or less)
• Has technical and field support

What to Look Stage 1: As the material starts to heat, it will begin to soften and bulge up slightly from the heat below it.
for During the
Heating of Stage 2: As the material begins to approach thermoforming temperature, the material will start to form ripples. Ripples
are a result of inherit stresses from the extrusion process. They are common in any extruded plastic.
KYDEX® Sheet
Stage 3: As the sheet approaches the thermoforming temperature, the ripples will start to smooth out. If the mate-
rial is formed at this point, your part would have a lower quality or have higher internal stresses in them than desired.
Possibly creating poor part definition and thinning in the side walls. If the surface temperature is already at the proper
thermoforming temperature, you may be heating too quickly. You should lower the oven settings and adjust the
dwell time.
SEKISUI SPI Stage 4: The material is now smooth, free of ripples along the clamping frame and sagging slightly (KYDEX® sheet
ISO 9001 and 14001 Certified
does not sag as much as ABS). This tells the operator that the core temperature is at the proper temperature. It is now
Customer Service
6685 Low St, Bloomsburg, PA 17815 USA ready to form. The combination of the proper surface temperature and core temperature is the key to achieving better
Phone: 800.325.3133, +1.570.389.5810 parts, less rejects and cost savings.
Outside the US: +1.570.389.5814
Fax: 800.452.0155, +1.570.387.7786
Email: [email protected]
Because we cannot anticipate or control the many different conditions under which this information and our products may be used, we do not guarantee the applicability of the accuracy of this information
Technical Service or the suitability of our products in any given situation. Users should conduct their own tests to determine the suitability of each product for their particular purposes. Data in the physical property table
represents typical values and are to serve only as a guide for engineering design. Results are obtained from specimens under ideal laboratory conditions. Right to change physical properties as a result of
Phone: 800.682.8758 technical progress is reserved. THE PRODUCTS DISCUSSED ARE SOLD WITHOUT WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR USE, EITHER EXPRESSED OR IMPLIED, EXCEPT AS
Fax: +1.570.387.8722 PROVIDED IN OUR STANDARD TERMS AND CONDITIONS OF SALE. Buyer assumes all responsibility for loss or damage arising from the handling and use of our products, whether done in accordance
Outside the US: +1.570.387.6997 with directions or not. In no event shall the supplier or the manufacturer be liable for incidental or consequential damages. Also, statements concerning the possible use of our products are not intended as
[email protected] recommendations to use our products in the infringement of any patent. Consult local code and regulatory agencies for specific requirements regarding code compliance, transporting, processing, recycling
and disposal of our product. Product not intended for use as a heat resistant surface. Texture, product grade and other conditions may cause variations in appearance.

sekisui-spi.com This information supersedes all previously published data.

© 2014 Sekisui Polymer Innovations, LLC. All rights reserved. KYDEX is a registered trademark of Sekisui Polymer Innovations, LLC. | 091614