What is Royalex?

Royalex is a multi-laminate that consists of layered ABS plastic, ABS Closed-cell foam, and outer layers of UV-protected vinyl. Before leaving the factory, the layers are vulcanized together creating the blank. Each Royalex blank is engineered for the specific canoe it is to produce. Here at Two Brothers Canoe we will strive for the strongest material layouts available.

Royalex starts out as a flat sheet, which is heated in a very large oven. During heating, the core expands, forming closed-cell flotation within the hull. At a specific temperature, the sheet is removed from the oven and placed on our custom table top where the mold is lowered on top of it, and the sheet is thermoformed with vacuum pressure into the hull shape. The result is a canoe that is very lightweight with superb strength, toughness and buoyancy. Royalex canoes are resistant to impact and abrasion with awesome structural memory.