This 5x10 sheet of Wilsonart Designer White makes a very nice screen surface.
Here's the shipping box in front of the 115" wide screen I've been using for a couple of years....
...it's simply drywall painted with Kilz2. I used Sherwin Williams Ultra White before that. And I've used BO cloth, parkland plastic, white Formica, 4x8 melamine, pull down screens, and Video Spectra screen material. Plus an untold number of painted mirror and rear projection screen tests.
I've been tempted to buy a $750-$1000 permawall screen for the past couple of years. It's actually not the cost that's holding me back, it's the potential for damage from my young sons and the neighborhood kids... there are several kids in our HT daily. They're usually well-behaved, but the young, grubby hands always go straight for the screen (as can now be proven by the current Kilz2 surface). The rest of our HT is durable and kid-friendly so a durable screen is essential.
I had a 4x8 panel of melamine MDF before. And it made a great, durable $25 screen. But 48" wasn't high enough for my preferred screen size.
My current projected image is 65"x116". I recently started re-assessing screen options because with the lights on and from very close-up at just the right angle, I can notice the drywall seam from using 8' sheets of drywall on a 14' screen wall.
This wilsonart is 61" high. So I can easily adjust to 61" x 108".
The wilsonart sheet unrolled nice and flat after I cut the 3 straps that kept it rolled in the shipping box.
I simply propped it up against the wall and tucked it behind my speaker columns. It held itself up pretty nicely... when I mount it, it'll be a couple of feet higher, but with the bottom edge on the floor, this left a nice strip along the top so we can see a comparison against my previous screen.
These are 1080i from a Motorola 6412 HD cable DVR deinterlaced to 1080p with a Lumagen HDP scaler. Canon S45 digital camera on tripod. No flash. Auto settings. Resized to 640 pixels.
In this screenshot, I stood by the screen to point at the seam. The image above my finger is the Kilz2 screen. The lower part of the image is the new Wilsonart sheet of laminate...
I tested from the side to check the viewing cone. Interestingly, it dropped off less than the Kilz2...
Very nice surface... affordable, zero spraypainting tools or talent required, durable, ideal texture, nice gain, true colors, and great contrast. I don't see any indication of glare or hotspotting.
These preliminary tests have proven that this surface is worth permanently adhering and trimming to my wall... I'm going to use black velvet masking adjustable between 16:9 and 2.35 aspect ratios.