Melamine sheet?

I don't think so. It might be a melamine top layer but melamine is usually veneered over the top of something like chipboard, MDF or birchply.

It’s solid grade laminate often referred to by trade name Trespa. It’s expensive and difficult to cut but is otherwise great for router templates.

Are you sure you can’t fit a 30mm bush to your router? This would be unusual.

No idea what it’s called but it’s some kind of dense nylon material, a very tough and durable plastic, like Corian but different.
I was given some large piece's which came from some condemned children’s play equipment and copied as many router jig’s as I could beg and borrow using an overhead router. The swarf that came off the cutter was like nylon string which was very strong.
I have used both worktop and stair jigs regularly for years without any problems.

Phenolic resin(jig) is the usual term you see describing these jigs. I think the actual stuff itself is called HPL sheeting.

Stands for High Pressure Laminate

If you can't get HPL, or it's too difficult to cut, then there is a product called Valchromat which is a high density fibreboard (as opposed to MDF - medium density fibreboard) that is sometimes used for jigs and MFT tops.

I've bought 600 x 600 x 19 pieces in the past from Atlantic Timber in Altrincham. Finsa do a similar product called Fibracolour but I haven't used it myself.

I've got a Dewalt D26204 plunge/trim router. The nearest guide bush I can find is 28 mm. Finding a 30 mm would be great as it would save me a few hours building a jig.

HPL - that seems to the stuff. Very spendy...

But failing that an excuse to finally buy some valchromat stuff should work. Thank you!

https://www.dewalt.co.uk/product/de6992-xj/guide-bush

Seems like there is a 30mm guide bush for your router. There’s probably non dewalt ones available too, you just need to match the fixing centres.

there is a product called Valchromat which is a high density fibreboard (as opposed to MDF – medium density fibreboard)

an excuse to finally buy some valchromat stuff should work.

I got a delivery for green valchormat in error a while back - I'd ordered mrMDF and the yard must have mistaken them up. They look very similar but holy mothering fudge is the valchromat heavy!

Before I had my own CNC machine if I needed jigs made up I'd draw them up and get a local sign company to make them up out of 19mm Foamex which is cheap and light and slick enough for a router to run around on freely. I can see the point of HPL jigs for trade applications but you'd need to be using a jig an awful lot for plain old MDF not to be sufficient. Try not to get drawn in by sponsored YouTubers who seem to have no work to show other than yet another thing to hold a thing in their workshop..... out of valcromat 🙂

King Starboard would work as a replacement material

https://www.kingplastic.com/products/king-starboard/

Thanks Andrw13. I spent ages going through DeWalts website and still missing that one.

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I've made some nice things using black Valchromat. I also made the blue guitar - but that was alder and maple.

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