Royalex was a composite material, comprising an outer layer of vinyl and hard acrylonitrile butadiene styrene plastic (ABS) and an inner layer of ABS foam. The layers are bonded by heat treatment. It was used to manufacture durable, mid-priced canoes. Its supplier closed out production of the material in 2014. Development Royalex is basically a board comprising a 'sandwich' of standard rigid ABS sheets in the core of which is an ABS layer designed to foam/expand during the heating stage prior to vacuum forming. Thus Royalex can be designed to form virtually any finished thickness to suit the end application. One just adds extra sheets. Since ABS has a poor resistance to UV a thin outer layer of UV resistant vinyl is generally included. This can be self-coloured or painted. ABS is a copolymer of rubber and thermoplastic: Acrylonitrile, butadiene, styrene. It was developed at US Rubber Co's Chicago plant by Bob Pooley and was simply called Royalite. US Rubber was later renamed Uniroyal - a blanket name to encapsulate their worldwide enterprises, which previously had separate names. Later, Bob Pooley and associates continued work on Royalite to introduce a foaming/expandable element. This was accomplished at the Uniroyal plant in Warsaw, Indiana. The resulting product was named Royalex to recognise the expanding core. Although extremely versatile as well as being very tough, the material was expensive compared to available alternatives. Even so, many industries were attracted to evaluate Royalex. Items produced included Caravans (vacuum formed in two halves) the top was a mirror image of the base so that only one forming tool was required. White Motors introduced a limited run of tractor cabs. A company was formed to produce a repro of the famous 'Coffin nosed' Cord Deusenberg. Gene Bordinat, Chief Designer at Ford designed a concept car in Royalex in 1965. This resulted in the 'Ford XP Bordinat Cobra'. The writer brought both of these cars to London, England to show at the International Plastics Exhibition and for exposure to the then extensive automotive producers. Royalex was extremely tough but if hit hard enough could be dented. If this happened such dents could be recovered by applying a hand held hot air gun which re-expanded the core to blow out the dent. The cost, as well as the need to accost a different build technique when using Royalex, mitigated against its acceptance in large scale production and eventually