ABS and PVC Fire-Rated Sheet
General Information

Royalite® Sheet is an engineered thermoplastic alloy designed for applications which have the most stringent flame and smoke requirements.


Royalite® is a thermoformable solution available in a wide variety of colors and textures.


Next to the low tooling costs enabled by thermoforming, Royalite® Sheet provides further benefits such as high impact strength, easy cleaning and resistance to UV rays, microbial growth and most commercial chemicals.


Royalite® is also available as granules. The Royalite® granules are mostly identical with their correspondent sheet grades. Due to mostly identical material properties (color, shrinkage, etc.) they are especially well suited for the production of injection molded parts which shall be assembled together with the Royalite® sheet.


Besides this, the most important feature of Royalite® Sheet is the compliance to the most stringent flame and smoke requirements, such as:


OSU 65/65,                         FAA Smoke Test,                               ASTM 162,                        UL94 V-0,

ASTM 662,                          FMVSS302,                                        FM4910 und                      DIN 5510.


By passing these specifications, Royalite® Sheet is especially suitable for applications in interiors of aircrafts, ships, trains and other mass transit items as well as for applications in industrial trucks and fork-lifts. Furthermore Royalite® Sheet can be used in medical diagnostic equipment (MRT-/CT-Diagnostic Centers) and in commercial technical buildings such as hospitals.


Royalite® sheet and granules pass and/or are listed in accordance to the most stringent flame and smoke specifications of several industrial segments. In these industrial segments they are mainly used for thermoformed or injection molded interior applications.



- Thermoformable enabling low tooling costs

- Impact strength

- Resistant to UV Rays

- Flame and smoke compliance

- Chemical resistance

- Cleanable … anti-microbial grades are available


Aircraft Interiors


Mass Transit



Medical Diagnostic Equipment



Commercial Building and construction




Colors and Designs

Thermoforming Guide


De-lamination or thinning out of the foam can occur with Royalite laminates in deep draw, concave areas and sharp corners. Therefore, draw ratios should never exceed 2.5 to 1; with a relatively safe ratio being 2.25 to 1. Also, a 0.25" minimum radius must be maintained in inside corners. Sharper radii are achievable if the depth of draw is one inch or less.



Standard vacuum forming machines may be used. However, because of the thermal conductivity of the foam in some laminates, the heaters on the flexible, "soft feel" layer side must be set differently than on the rigid ABS or ABS/PVC side. Typically the flexible side heaters run at about one half of the output of the rigid side heaters, depending on the thickness of the rigid substrate. The greater the rigid thickness, the greater the output differentials. It is normally best to run the rigid ABS or ABS/PVC substrate toward the top heaters and heat the rigid side at about standard heat settings.


The sheet should be heated with a soaking type heat. The object of the heating cycle is to get the flexible side surface to its proper temperature while simultaneously reaching 330°F to 380°F on the surface of the rigid substrate. The flexible side should not be overheated nor heated too quickly as this will cause the skin to blister and the foam under the skin to rupture and break down the cell structure.


The thermoforming temperature ranges for Royalite laminates are as follows:


Flexible "soft feel" side


R104 and R105 laminates: 280°F - 320°F*


Rigid ABS or ABS/PVC side: 330°F - 380°F*


*measured with infra-red sensor


Radiant type heat is preferred; therefore ceramic heaters are the elements of choice. The rigid substrate material can be heated quickly while still using a soaking type heat for uniform forming. Nichrome wire and kelrod heaters also work, but it may be necessary to screen out some of the infra-red heat to better allow the heat to penetrate the foam layer. It is also good processing technique to deliver the heated sheet to the forming station as soon as possible to prevent the flexible surface from chilling too much. This will have a secondary effect of giving you better detail on the part.



Most types of molds from temperature controlled aluminum to wood molds will work. However, different types of mold materials wills result in vastly different cooling cycles, so temperature controlled molds are the most efficient.


Typical forming methods employed are:


1) Standard Drape


2) Inverted Drape


3) Snap Back


As a rule, plug assist are not used except in trimmed out areas.




It is best to use spiral down-fluted routers coming in from the foam side. This will not eliminate, but will minimize fraying. Dies with beveled edges produce excellent results, especially when cutting through the foam side first. This tends to produce a smoother edge finish. Standard plastics drilling techniques can be used, but when sawing this material, sawing from the flexible side is recommended to minimize fraying.


Standard Sheet Thicknesses

Sheet Textures