1. Overview

Using resin pricing to compare thermoforming materials is misleading because real-world purchasing is overwhelmingly sheet-based, and sheet markups differ substantially by material class. KYDEX, PETG and PC carry very high sheet-level premiums. Commodity sheets like HIPS and HDPE remain the lowest-cost.

This guide uses actual sheet pricing + density-adjusted weight estimates to derive realistic per-pound figures.

Materials Covered: HDPE, PP, PVC, HIPS, ABS, PETG, PC, KYDEX T
Price Basis: Typical U.S. retail or small-quantity distributor sheet prices converted to USD per lb.
Important note: plastic prices can fluctuate but their prices should remain relatively stable compared to each other except for extreme supply chain disruption, like around the 2020 COVID-19 pandemic or the 2021 Texas ice storm. Pricing for this guide was researched on 11/21/2025 and may be different in the future. Pricing was also based on low volume purchases from distributors, much lower pricing is available in bulk – again, bulk prices should be relatively comparative.

2. Cost Ranking (Least to Most Expensive)

Using the sheet-derived figures:

1. HIPS (~$2.9/lb)

2. HDPE (~$3.0/lb)

3. ABS (~$3.2/lb)

4. PVC Type I (~$3.2–4.3/lb)

5. PP (~$3.3/lb)

6. PETG (~$4.8–6.2/lb depending on vendor)

7. PC (~$5.5/lb)

8. KYDEX T (~$12.9/lb)

3. Interpretation

3.1 Commodity Thermoforming Plastics

HIPS, HDPE, ABS, PP, PVC

These sit close in cost, with HIPS and HDPE at the bottom and PVC/PETG rising with density. ABS is the workhorse for enclosures; HIPS is the cost-leader for cosmetic parts with mild structural requirements.

VC densities (1.35–1.4 g/cc) push sheet weight up significantly, explaining why PVC is no longer “cheap” per pound once sold as sheet.

3.2 Premium Thermoforming Plastics

PETG, PC

Both command significantly higher sheet markups. PETG’s clarity and formability justify the increase; PC remains the premium option for impact resistance.

3.3 FR / Specification-Driven Plastics

KYDEX T

KYDEX is not remotely comparable to commodity plastics in cost. The price premium reflects:

• PVC/PMMA alloy

• FR performance

• Tight color/control tolerances

• Limited producer base

• Application certification requirements

Your internal $42/lb effective cost is entirely plausible for cut sheets, scrap-factored pricing, or when allocating overhead and waste, because:

• KYDEX is already nearly $13/lb at the best case full-sheet retail level

• Cut-to-size rates scale aggressively

• Scrap factors for FR materials are often 2× commodity plastics

• Freight and storage add materially due to density and limited stocking

4. Bottom Line

Sheet pricing fundamentally changes the cost picture:

• HIPS and HDPE are the true cost leaders for thermoforming when priced as sheet.

• ABS and PP occupy a stable middle, typically ~3.2–3.3 per lb.

• PVC grows more expensive than ABS or PP per pound because of its higher density.

• PETG and PC jump to the next tier, often 2× the commodity materials.

• KYDEX is orders of magnitude above commodity materials and even far above PC.