Kydex - the robust alternative to leather
Kydex is a cheaper alternative to leather. You can use it to make your own tool holders and covers with a little heat. In this blog, we explain everything you need to know about plastic and show you how you can use it in your workshop.
What is Kydex?
Kydex is a versatile thermoplastic material, i.e. it can be moulded by heating. It is usually offered as sheets in the size of a DIN A4 sheet with a thickness of 1 to 3 mm. When heated to approx. 130 to 160 °C, Kydex becomes temporarily soft and then adapts flexibly to almost any shape. After cooling briefly, it becomes solid again and can be further processed. This process can be repeated almost as often as required.
What are the advantages of Kydex?
Robust: Kydex panels are flame-retardant (in accordance with DIN 4102 B1 UL 94V-0), scratch-resistant, impact-resistant, weather-resistant and chemical-resistant.
Simple processing: Kydex can be cut, sawn, drilled, sanded and polished using normal woodworking tools.
Easy to mould: A standard heat gun or a small oven (pizza oven) is sufficient to heat the Kydex sheets. After just a short time (approx. 5 to 7 minutes), Kydex is heated to 130 to 160 °C and is flexible.
Adaptable: Warm Kydex adapts very easily to complex shapes and surfaces. When warm, it covers the tool like a rubber blanket and retains its shape after a short cooling time (approx. 3 to 5 minutes).
Correctable: If something goes wrong, you can reheat the Kydex. It becomes soft again and usually returns to its original plate shape.
Bending Kydex
You don't need an expensive press to adapt Kydex to the shape of a tool. For very simple moulds, the heated Kydex plate can be placed directly on or around the tool and fixed in place with simple clamps.
If the shape of the tool is more complex, the Kydex can be pressed into place with one or two pieces of firm foam (insulation mat or packing material). Depending on the shape of the tool or cutting edge, you can place the foam on one side so that the Kydex remains flat on the opposite side, or you can place a layer of foam on the top and bottom so that the Kydex adapts to the shape of the tool all round. Test in advance whether the foam can withstand the temperatures; it must not melt. If necessary, place a sheet of paper between the Kydex and the foam to prevent it from sticking.
As with wet moulding leather, you can also shape Kydex using a tool. To do this, you need a simple wooden mould or a frame that stretches the Kydex over the tool. This technique is particularly suitable for holsters where you mainly want to remove the contour of the tool and keep one side flat.
Tip: Tape off sharp edges with adhesive tape for their and your own protection! You should also mask off sensitive surfaces or plastic handles before placing the hot Kydex on them. Taping creates a small gap between the tool and the Kydex, which makes it easier to insert the tool into the sheath or holster.
Further processing
As written, Kydex can be easily processed with normal tools. To join several parts, Kydex can be glued with epoxy glue, for example. For permanently strong and durable connections, we recommend riveting or screwing the parts together. Eyelets are very often used to connect Kydex. They are easy to work with and join the Kydex parts permanently. Leather straps or cords can also be pulled through the eyelet openings to attach the sheath or holster. Screw rivets, also known as "Chicago screws", are suitable for joining three or more layers of Kydex.
Combine with leather
The combination of Kydex with leather enables many other forms of use. For example, you can permanently protect the inner part of a leather sheath against cuts from a sharp blade with a precisely fitting Kydex inlay. With a Kydex belt clip, a leather holster can simply be slipped onto a belt without having to pull it out of the loops.
