Rexolite RAlph

is a rigid, transparent insulating material made by an irradiation cross-linking process. Rexolite is one of the best dielectric materials known with a dissipation factor 200 times better than nylon.

In contrast with other high temperature, ultrahigh frequency dielectrics, Rexolite has the rigidity and ability to resist deformation under load. These characteristics are extremely important where assembled insulators must withstand compression without yielding and loosening over long periods of time.

Rexolite materials are cast in liquid form and cured to make sheets, then ground to size, coated with a patented adhesive polymer and clad in a laminating press. Homogeneous and isotropic electrically as well as radiation resistant, they are available clad with electrodeposited or rolled copper on one or both sides.

Because it is cross linked polystyrene, rexolite has excellent machinability and shock resistance when compared to other unreinforced thermoset materials.

Rexolite 1422 has a combination of good physical and excellent electrical properties including low and stable dielectric constant. These properties make this material suitable for use in microwave lenses as well as for precision components.

Dielectric Properties of Rexolite® -
Outstanding! Rexolite® maintains a Dielectric Constant of 2.53 through 500Ghz with extremely low dissipation factors. Rexolite® is ideal for microwave lenses, microwave circuitry, antennae, coaxial cable connectors, sound transducers, TV satellite dishes & sonar lenses. Other applications for Rexolite® include nondestructive material testing devices, surveillance equipment, radar windows, radomes and missile guidance system housings. One interesting application for Rexolite® are radar lenses which are used in mapping the Earth's surface from fast, high altitude aircraft.

High Voltage Insulators
Rexolite's® ability to withstand high voltage is important for producing gap switch houses, capacitors and other components. Rexolite® is proven superior to Acrylics, Epoxies, Urethane and other plastics for dendriting resistance. (Failure caused by electron bombardment)

Radiation Resistance
Rexolite® is superior to most plastics. Little change in dielec-tric loss over a wide range of exposures up to 1000M rads. Rexolite® has superior resis-tance to mechanical deterioration by ionizing radiation.

Rigidity & Dimensional Stability
Rexolite® exhibits no permanent deformation or plastic flow under normal loads. All castings are produced stress-free and do not require stress relieving prior to, during or after machining.

Wide Temperature Range
Recommended operating temperature for Rexolite® 1422 is 100C; Glass transition temperature is 114C; maintains excellent dielectric properties from -270C to 176C (no load - short time).

Rexolite's® Optical transmission is approximately equal to Acrylic - (87% visi-ble light, 1" thick). Refractive index 1.59 @ 589 nanometers, 1.604 @ 486 nanometers and 1.585 @ 656 nanometers. Rexolite® is utilized in combination with Acrylic lenses for color correction.

Water Absorption
Less than .08%, Rexolite® type 1422, has been immersed in boiling water for 1000 hours without change in dielectric constant.

Rexolite® handles well in all machining operations. Tool configura-tion is similar to those used on Acrylic. Due to high resistance to cold flow and freedom from stress, Rexolite® is easily machined by water jet, laser beam to very close tolerances. Accuracies of .0001 can be obtained by grinding. Crazing can be avoided by using sharp tools and avoiding excessive heat during polishing. Stress relieving of Rexolite® is not required before, during or after machining. Always maintain sharp tooling.

Sub-zero Properties
Rexolite® maintains a Dielectric Constant of 2.55; at -270C the dissipation factor is .00019.

Rexolite® 1422 burn rate is less than 1 inch per minute.

Copper Cladding
For printed circuit boards. Available in Rexolite® 1422 or Rexolite® 2200, copper thickness range from one-half ounce to two ounce copper.

Environmentally Friendly
Rexolite® is nonhazardous, contains no ingredients harmful to the environment.

"Properties", Applications" and "Availabilities" for the Rexolite Sheet and Rod are at the bottom of this page.

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 Rexolite Sheet
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0.10, 0.15, 0.20 require a
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 Rexolite Rod
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Minimum $50.00 for internet orders. Orders less than $50.00 will be charged a $25.00 service charge.
The price given on this page is a material quote only. It does not include the additional shop processing fees.


Properties, Applications and Availabilities for the Rexolite Sheet and Rod




Resistant to load deformation UHF, VHF and microwave insulators Rod: .062" to 8.000"
Outstanding dielectric qualities Communication, electronic equipment Plate: .032" to 6.000"
High radiation resistance    

Rexolite® 1422 Properties Chart



Test Method

Typical Value

Dielectric Constant 1 Khz to 500 Ghz ASTM-D-1531 2.53 +/- .03
Dissipation Factor @ 1 Khz ASTM-D-1531 0.0001
  @ 1 Mhz ASTM-D-1531 0.0002
  @ 30 MHz ASTM-D-1531 0.0002
  @ 10 Ghz IPC-TM-650 0.0001
  @ 120 Ghz Army Electronics 0.0008
  @ 500 Ghz Army Electronics 0.0003
Dielectric Strength (.010 Tk) ASTM-D-149  
Short time (volts/mil) ASTM-D-149 2100
Step by step (volts/mil) ASTM-D-149 2000
Volume Resistivity (Megohm-cm) PC-TM-650 1.1x10 16
Surface Resistivity (Megohm) PC-TM-650 4.5x10 14
View Rexolite MSDS Sheet      
View Rexolite Data Sheet      


Test Method

Typical Value

Temperature Range (Recommended)   -60 º C to 100 º C
Glass Transition Temp.   114 º C (237 º F)
Specific Gravity ASTM-D-792 1.05
Tensile Strength ASTM-D-638 10,500 psi
Tensile Modulus ASTM-D-638 4.5 x 10 5 psi
Compression Strength ASTM-D-695 18,000 psi
Flexural Strength ASTM-D-790 18,000 psi
Coefficient Thermal Expansion ASTM-D-3386 7.0 x 10 -5 C
Thermal Conductivity ASTM-E-1530 1.23 Btuin/hrft2ºF
Water Absorption ASTM-D-570 .08 % Max
Poisson's Ratio   .42
Acoustic Impedance   2.5
Velocity of Sound   93 x 10 3 Inches/Sec.
Rockwell Hardness ASTM-D-785 R130
Izod Impact Strength ASTM-D-256-97 1.2 ftlbf/in2
Izod Impact Strength Un-Notched   6.0 ftlbf/in2
Out-Gassing @ 125 º C ASTM-E-595  
  TML   .04 %
  CVCM   .01 %
  WVR   .03



Alkalis (Sodium/Potassium Hydroxide) No effect
Alcohols (Methanol/Isopropanol) No effect
Aliphatic Hydrocarbons (Pentane- Cyclohexane/n-Heptane/n-Hexane) No effect
Mineral Acids (Hydrochloric/Sulfuric/Nitric) No effect
Aromatic Hydrocarbons (Benzene/toluene/xylene/styrene) Swells
Chlorinated Hydrocarbons (Carbon Tetrachloride/Chloroform) Swells


Typical Value

Total Transmission 1" thick 87%
Refractive Index 20C 436 Nanometers 1.614
Refractive Index 20C 467 Nanometers 1.607
Refractive Index 20C 480 Nanometers 1.604
Refractive Index 20C 508 Nanometers 1.599
Refractive Index 20C 546 Nanometers 1.594
Refractive Index 20C 589 Nanometers 1.589

Rexolite's® Standard Shapes & Sizes



Rexolite® 1422 rod from .030 to 9" in diameter.    
Rexolite® 1422 sheet from .010 to 6" thick.    
Rexolite® 2200 sheet from 1/32" to 1/4" thick.    
Copper clad Rexolite® 1422 from .010 to 1/4" substrate.    
Copper clad Rexolite® 2200 from 1/32" to 1/4" substrate.    
Rexolite® Adhesive #12517 in two half pint cans.    
Rexolite® rings, tubes, larger rod and sheet available upon request.    

Chemical Resistance



Alkalies, Alcohols, Aliphatic Hydrocarbons & mineral acids have no effect on Rexolite®.
      Aromatic hydrocarbons cause swelling and should be avoided.

Military Specifications



Rexolite® 1422 conforms to military specification LP-516A, type E2, formerly MIL-P-77C-E2.