Royalex

Royalex is a composite material formerly used in the manufacture of canoes and other small watercraft. It was prized for its durability, light weight relative to its strength, and its ability to withstand impacts and abrasion.

The material consists of an inner core of acrylonitrile butadiene styrene (ABS) foam sandwiched between layers of ABS plastic and an outer skin of vinyl. The ABS provides structural rigidity, while the vinyl offers abrasion resistance and weather protection. The foam core contributes to buoyancy and helps dampen sound.

Royalex offered a good balance between performance and affordability, making it a popular choice for recreational boaters. Its flexibility allowed it to deform upon impact rather than crack or shatter, making it suitable for navigating rocky rivers and shallow waterways. The material could be molded into complex hull shapes.

The production of Royalex ceased in 2014 when its sole manufacturer, Spartech, discontinued its production. This led to a significant impact on the canoe manufacturing industry, as many companies relied on Royalex for a substantial portion of their product lines. Alternative materials, such as polyethylene, T-Formex, and advanced composite layups, have since been used to replace Royalex in new canoe production. Used Royalex canoes remain popular due to their desirable properties and long lifespans.