Why HDPE

High Density Polyethylene (HDPE) is a thermoplastic polymer that one of the most common plastics in use today. It can be formed into sheets, extruded into profiles or molded into any shape.  It can be dyed to any color imaginable and can have a myriad of additives that provide a range of desired properties.

It is best-known for its high strength-to-density ratio and broad resistance to chemicals.

It is easy to work with and easy to weld using extrusion welders.

HDPE is practically impact-proof—far more so than aluminum or fiberglass.  It is very abrasion resistant, shatter proof and difficult to deform. It can withstand continuous abuse without harm. It won't crack, dent, or tear except under very extreme abuse. If ever damaged, the damage stays localized and won't spread.

HDPE also exhibits a good degree of flexibility; it will flex during a heavy hit, then immediately rebound to its original shape.  Due to this flexibility, it does not accrue fatigue stress as with either aluminum or fiberglass. 

HDPE is unaffected by corrosion as with metals, and will not pit, rot, decay, or delaminate. Minimal fading due to sun exposure is about the greatest effect and can be alleviated by proper care and resurfacing methods.

It is available as UV-stabilized for outdoor use; it is waterproof and weatherproof and is impervious to fuels, oils, cleaners and most solvents.

Repairing HDPE is both easy and economical and can be readily handled by one skilled with the material.

HDPE is lightweight, clocking in at only 0.0343 lbs. per cubic inch. It has a density a bit less than water, making it buoyant. It is 1/3 the weight of aluminum and 1/2 the weight of fiberglass.

As an example, I can fabricate items to 3/8" marine board and keep to the same weight as 1/8" aluminum sheet or 1/4"-thick fiberglass.

Material can be kept thin for weight savings or thick for extra durability, without adding much weight.

Furthermore, HDPE is less dense than water, making it buoyant. That advantage can be exploited on boats.

HDPE board is available in an array of off-the-shelf colors.

This color palette allows you to pick one that closely matches your boat or project. No painting required. Alternatively, do you already have a color of HDPE marine board (or other HDPE board on your boat/project)? I can match it! Just give me the color and I'll acquire it.

Weld wire is often available to match as well, giving your project a clean look.

Note:

Custom colors are available but must be fully discussed first and I must be allowed some time to work this. Minimum quantities apply from the manufacturers and may make a project economically intangible except on very large scale or volume.

I can get weld wire to readily match most off-the-shelf colors. Lead times and additional costs may apply but are usually reasonable.

Plastics and environmental friendliness don't always go hand-in-hand.

However, HDPE has proven to be so. It is also healthier to the fabricator.

Unlike fiberglass, no toxic chemicals or solvents are required during fabrication. No resins, styrene, or MEK. The only solvent I use is acetone in small quantities for cleanup. Unlike fiberglass shavings, those from HDPE are benign, large, and fairly soft and pose no inhalation risk or irritation to the body.

Welding and heat forming is also safe. Performed correctly, no smoke or fumes are created. The potential health effects from breathing fumes are removed.

The production of raw HDPE requires far less energy to produce over raw aluminum. Some sources indicate it has only 20% of the carbon footprint of aluminum.

Welding HDPE is faster and less energy intense over aluminum. Electricity use is only 10-20% of what is required to weld aluminum.

HDPE is very recyclable. The most common method is via 'regrind', where the material is ground up then mixed with virgin material and simply reformed into sheets.

Paints do not adhere well to it and is not recommended. As a boat material, marine growth has difficulty sticking to it. For underwater applications, no bottom paints are needed. Thus no toxic effects of paint. This is offset by the availability of colors.

No chemical leeching. HDPE is very inert. No chemicals from it (also due to the lack of paint) will leech into the environment, keeping our plants and wildlife safe. In fact, it is FDA-approved for food and water contact.

I pride myself in keeping it American. Most HDPE is made right here in the United States and I will always opt for US-made material whenever I can. Made in America, with American-made materials. That is what you can expect.

Note:

Some industrial grade HDPE may be foreign or domestic, and depends on the supplier.