King StarLite® XL is an economical, cellular (closed cell), utility sheet made from select high-grade King StarBoard® recycled high-density polyethylene. The polymer is up to 35% lighter than the original King StarBoard®. It is the product of a proprietary process called K-Stran™, the most advanced manufacturing process for superior flatness and consistency. King StarLite® XL has a matte finish on both sides of the sheet. It is environmentally stabilized to withstand the harshest outdoor conditions. King StarLite® XL will not rust, delaminate or rot when exposed to UV, humidity or water. It is ideal for a variety of marine applications from boat components, to upholstery substrate and other behind-the-scenes applications where edges aren’t visible. The polymer sheet never needs painting or refinishing, works like wood, and is easy to fabricate with common woodworking tools and techniques.

King StarLite XL is upgradable to King MicroShield® with an advanced antimicrobial technology for protecting the product surface against stain and odor causing bacteria, algae and fungi.*

For more information about King MicroShield®, please visit product page.

Disclaimer: King MicroShield® may affect color.

Where to Buy

*For bacteriostatic, fungistatic, & algistatic properties. This product is exempt from registration under 40 CFR 152.25(a). King MicroShield® effectiveness verified by ISO and ASTM standards. This product does not protect users or others from disease-causing bacteria. Always clean this product thoroughly after use.


Standard Sheet Size

in: 60″ x 96″
mm: 1524mm x 2438mm


Standard Gauges

in: 1/4″ 3/8″ 1/2″ 3/4″
mm: 6.4mm 9.53mm 12.7mm 19mm

Approximate Weight

lbs: 40 lbs 56 lbs 72 lbs 108 lbs
kg: 18.14kg 25.4kg 32.6kg 49kg

Tolerance information:
Gauges 1/4″ up to 3/4” ± 5% | Length and width plus only at room temperature

Custom sheet sizes and gauges available

Physical Properties
Properties Units ASTM Nominal Values
Density g/cm3 D792 *0.77 & 0.7187
Tensile Strength @ Yield psi D638 >3,300
Tensile Modulus psi D638 165,000
Elongation @ Yield % D638 9.6
Flexural Modulus psi D790 130,000
Flexural Stress @ 5% Strain psi D790 2,990
Compressive Properties 10% Strain psi D695 2,910
Durometer Shore D D2240 64.9
Izod Impact Resistance ft.lbs./in.2 D256 1.4
Heat Deflection Temp. 66 psi ºC (ºF)  D648  87ºC (188ºF )
Screw Holding Strength lbs D1761 325
Flammability Rating UL94 HB

All values are determined on specimens prepared according to ASTM. Nominal values should not be interpreted as specifications.
King StarLite® XL is made entirely from FDA and USDA approved material.
*Nominal value 0.77 density applies to 1/4″ gauge only


Additional Information

General Applications:

  • Environmentally stabilized to withstand tough
    marine conditions.
  • Matte textured on both sides.
  • Will not swell, rot, or delaminate when exposed to
    humidity or water.
  • Resists odor even in wet environments.
  • An excellent substrate for mounting instruments.
  • Able to securely hold staples and screws.
  • Available in large sheets up to 60” x 96” or 48” x 96”.
  • Custom sheet sizes available.
  • The perfect lightweight replacement for plywoods
    or MDF.
  • Flexes without breaking, unlike plywood or PVC
    foam products.
  • Easy to clean and never needs refinishing.
  • Perfect for upholstered parts. Bends without breaking.
  • Easy to fabricate using standard woodworking tools.
  • Proven on thousands of boats and yachts.
  • Experienced boat builders and boaters know the
    King StarBoard® brand and trust it more than any other.