Thermoforming Boltaron® 4335: A Technical Interview with Micah Chaban, Founder and VP of Sales at Rapid Made
Introduction
Micah Chaban is the co-founder and Vice President of Sales at RapidMade, a U.S.-based advanced manufacturing firm specializing in additive manufacturing, custom thermoforming, and CNC machining. With a background in business operations and a hands-on approach to client solutions, Micah has helped position RapidMade as a trusted partner for companies seeking faster lead times, responsive engineering support, and cost-efficient custom fabrication. Under his leadership, RapidMade has grown into a key player in modern manufacturing—especially in high-performance plastic forming, including materials like Boltaron® 4335.
What makes Boltaron® 4335 stand out in thermoforming applications?
Boltaron 4335 is a material that really checks all the boxes for performance, safety, and production efficiency. It’s incredibly tough—its notched Izod impact strength is 18 ft-lb/in, which is significantly higher than what you typically see in this category. But beyond just numbers, it forms consistently, holds its shape after cooling, and doesn’t require pre-drying. That last point is important because it saves time and reduces scrap. For us and our customers, that means faster turnarounds and better yield.
It also has top-tier flame resistance, meeting UL 94 V-0 and FAR 25.853. So whether you’re producing parts for aerospace, medical carts, or kiosk housings, it meets the specs you need without overcomplicating the manufacturing process.
How does it compare to KYDEX® T, which is often the default in aerospace?
KYDEX T is definitely the name everyone knows, and it has a solid reputation. But Boltaron performs just as well, and in some cases better. For example, you’re looking at slightly higher impact resistance, comparable flexural strength, and better forming temperatures—around 335 to 370°F versus KYDEX T’s 365 to 390°F. That wider window helps reduce errors during forming.
Another practical factor is procurement. KYDEX T usually comes with a minimum order of 600 pounds and lead times that can run up to 8 weeks. Boltaron, by contrast, can be sourced at 500 pounds minimum and has a lead time around 4 weeks. That flexibility is crucial for customers who can’t afford to sit on large inventories or wait months to launch production.
What industries are best suited for this material?
We see strong adoption in aerospace and aviation, particularly for cabin components, paneling, and storage compartments. But it’s just as well-suited for high-durability kiosks, point-of-sale machines, and medical device enclosures. Its ability to take custom colors and textures also makes it great for visible parts—so you’re not just getting performance, but also a good finish.
We’ve also had clients use it for protective housings in rugged electronics—environments where impact and temperature resistance really matter. Anywhere you need strength, flame compliance, and a reliable forming process, it’s a good candidate.
Are there any limitations or considerations fabricators should keep in mind?
You always want to match the material to the forming method and part geometry. Boltaron is very forgiving, but with any rigid thermoplastic, you’ll want to monitor tool temperature and maintain uniform heating to avoid warping. But honestly, it’s easier to form than a lot of its competitors.
Also, because it’s PVC-based, it can’t be used in applications where high-temperature exposure exceeds its deflection threshold—around 161°F. If your part lives in a high-heat zone, you might need to look at engineered polymers.
What makes RapidMade a strong partner for thermoforming Boltaron 4335?
We’re not just a job shop—we’re a design and engineering partner. We work with clients from material selection through prototyping to full-scale production. We’ve run hundreds of Boltaron projects, and we know how to optimize every step: heating profiles, tooling specs, trimming strategies, and assembly. That experience saves time and reduces rework.
Because we handle everything in-house—from design and CNC tooling to forming and finishing—we can move quickly and control quality. That’s especially valuable for companies under pressure to iterate designs or hit tight deadlines.
Ready to make the switch to Boltaron® 4335 or explore your thermoforming options?
Reach out to RapidMade at [email protected] or visit rapidmade.com for expert consultation, custom quotes, and turnkey manufacturing solutions.
