G'day;
One minor downside of kydex: It's moulded around the knife under heat and pressure tending to give a fairly snug fit, this means that any dirt of grit that is trapped inside it can scratch the knife blade. It's not uncommon to see blades with fine scratches along the length of the blade due to this.
I have been forming KYDEX and other polymer sheet since 1989, and make around 3,500 to 4,000 KYDEX sheaths per year for both knives, and firearms.
KYDEX has it good points and its bad. In reference to the "scratches?" KYDEX has a wearability or durability hardness of 57 on the Rockwell C-scale. This is a little harder than the majority of commercial knives on the market today. Commercial cutlery overall aren't made that "hard" for a number of reasons that I want get into now. One other thing; The "rattle" noise can be removed or quieted with dampers molded into the sheath as it is no big deal. If it is too tight in the case of a sheath knife wrap the blade before molding and give it a slightly larger form. Just the thickness of a layer of tape on each side will do wonders believe it or not.
KYDEX is an acrylic PVC compound thus it is "wear resistance" by the addition of the acrylic. Heat, pressure and/or vacuum is the preferred method of molding KYDEX as with PVC sheet, but the acrylic polymers are what makes KYDEX stand out.
KYDEX has two enemies; number one is
high heat and the other is
extreme cold.
I read about a guy who fell from a tree 3-4 meters down. He landed on his Kydex sheath for his A1 Fällkniven and it broke!
I saw one of these knives in my shop recently for the first time. The sheath was a molded one piece plastic of some kind? I didn't think it was KYDEX myself, but I could be wrong. If it was I could see why it might have broken from the design.
I carry a WOO neck knife in my truck with a length of parachute cord wrapped around the steering wheel housing and the knife hanging right at my ignition key. It is near invisible to see, and no one thinks anything about it if you have your hand in this area of the vehicle so it is easy to deploy. The insides of a truck in our part of the world can get up to 250* F in the summer days, but I have never lost that sheath. Now if the knife and sheath were to be thrown up on the dash, I would assume it would deform. (KYDEX molds at 325* F)
some may find that the Livesay sheathes are a little too secure.
Neck sheaths have to be secure or the knife will fall out. Other sheaths such as the In The Waist band, and Boot Knife styles sheaths can and do need to be loose fitting so as to facilitate easy removal.
Leather or KYDEX? I love a nice leather sheath and make them for many of my custom knives, but I do not use it on combat utility or survival cutlery. Leather will not hold up in the field like KYDEX will. KYDEX will not absorb moisture, mildew, or rot where leather will absorb over 250 times it's weight in moisture, mildew, and rot. It is the worst material for a sheath you can use in semi-tropic and tropical environments. Like I said I spend a lot of time in Central & South America now and leather sheaths want last a month in the jungle. If it doesn't rot something will eat it. KYDEX is the number one preferred sheathing material for military contracted knives right now. It isn't pretty sometimes, but it serves a purpose that leather can't fill.
Thanks
Newt Livesay