I'm the National Sales Manager at United Industries and came across this post today. I would like to know if you have received your sample kit(s) yet and how they worked for your application. We have larger samples (2' x 3') available for your testing if needed. I'm not sure that the 8" x 10" samples that come in the standard sample kit would be large enough for your needs so if would like the larger kits please feel free to contact me with your request.
I've noticed that some of the concerns were the durability of the board. Simply put, anything that would damage projections screen would damage our boards as well (wiffle ball bats, kids, sharp object, etc.). As some of you have pointed out though, when damaged you are out less than $100.00 for a screen vs. much higher cost screens marketed to the projection screen industry.
The Ultra Board product has a 15 mil litho grade styrene liner on each side. Ultra Board is the product that you see in many of the department stores overhead signage programs such as Wal-Mart, Home Depot, Lowe's, and Sears.
Ultra White DP has a brighter white point than the Ultra Board and is slightly more rigid. The cap on each side of the sheet is an 18 pt. poly coated paper.
Ultra Plus is capped with 1mm PVC on each side and is our most rigid board. The surface has a little more texture than our Ultra Board or Ultra White DP. Ultra Plus would by far be more durable than most screens available in the market. Ultra Plus most likely wouldn't give the same visual quality as Ultra Board or Ultra White DP but I can't say that for certain.
We can produce Ultra Board and Ultra White DP up to 60" x 120". Custom sizes are available so if you needed exact sizes in order to fit screen ratios for projectors we can produce those for you, minimums do apply (100 sheets). Many of our distributors can cut custom sizes for you for quantities under 100.
I hope I have been able to address most of your questions but if you have any further questions, concerns, or need samples please feel free to contact me. I'd be happy to help you in any way I can.