ABS-Sheet with a closed-cell foam core
General Information

Royalex® is an ABS laminate with a core of expanded, closed-cell foam.


This tough, lightweight sheet is created by laminating core, substrate and surface plies into a single monolithic unit. The core plies are compounded with a chemical blowing agent that expands under heat to form a low density, closed-cell foam core.


This core imparts stiffness, resilience and superior shock absorption. It resists water absorption and adds a substantial measure of buoyancy and insulation.


The substrate provides strength and high impact and fatigue resistance.


The surface ply gives color, texture, strength and now improved abrasion resistance over previous designs. Royalex® will not rust and resists most industrial chemicals, oils and greases.


Royalex® is offered in a wide variety of standard or custom colors. It is designed for thermoforming and can be delivered in a variety of sheet sizes.


Due to its lightweight strengths, Royalex® is the ideal choice for robust canoes, Formula K cars, bus fenders or any complex shape.


Royalex® is laminated to order, so its actual physical properties are tailored to your specifications.


Pound for pound, Royalex® has greater rigidity and impact strength than steel, aluminum or fiberglass. Its lightweight strength makes ROYALEX the ideal choice for canoes, suitcases, bus fenders, stiff covers or any complex shape that needs to withstand rough environments.



- Excellent stiffness and resilience
- Superior shock absorption
- Resists water absorption
- Substantial proportion of buoyancy and insulation
- High impact strength and fatigue resistance
- Improved abrasion resistance
- Resists most industrial chemicals, oils and greases.










Shower basin



ROYALEX can be heated in standard thermoforming ovens, but air convection ovens or preferably halogen heating elements are recommended. ROYALEX is typically formed on fiberglass or epoxy tooling, but any tooling such as wood or aluminum can be used. It is readily hand-formed for prototyping. Care must be taken in forming so as not to overheat the sheet. Stock temperatures of approximately 280°F- 300°F are recommended for proper forming. As with any thermoplastic material, care should be taken to account for the coefficient of thermal expansion when considering design parameters. Please contact us for data relating to your specific application equipment.


You can machine, saw, drill, rout and grind this rigid ROYALITE sheet with conventional plastics fabricating tools. It can be painted or repaired very easily. As long as proper procedures are followed, you can join it to other materials, or itself, by adhesive bonding and by mechanical fasteners such as screws and rivets. Please contact us for specific recommendations.

Colors and Designs

Colors & Textures

ROYALEX is offered in a wide variety of standard or custom colors in Smooth only. Please contact us for specific information.

Product definition

Technical Informations


Typical physical characteristics of a fully expanded Royalex blank with 1-3-4-3-1 construction.  These properties do not necessarily change linearly, so we recommend that you contact us for proper performance specifications for your application.


Standard Sheet Sizes

ROYALEX is a custom hand laid up material that is available in a variety of constructions.


Sheet Sizes – maximum width 8 ft. 6 in.


Seamless sheets – maximum 4 ft. 8 in. wide and 25 ft. 0 in. long


Seamed sheets – maximum 8 ft. 6 in. wide and 25 ft. 0 in. long


Skin and core thickness can be varied to meet your specific needs. Fire-rated sheets are available.