If you're making that many kydex sheaths it's plain you have some insight into the material in other regards besides scratching of blades. I'm curious how you and your clients feel out kydex stiffness, in terms of supporting the blade and more importantly protecting the wearer from the blade. Leather has serious issues in the latter regard, where a very sharp and stiff blade might easily cut through a sheath and into the user's body. With a kydex sheath, and especially with the thinner sheets, is this not really a problem at all? I'm thinking of wearing a belt sheath for example, where a stiff, shorter blade is worn towards the front of the hip and then the user bends very sharply forward, folding the sheath between hip, belly, and thigh. Not a problem really? To read Jay Fisher go on about it on his site one might thing using plain kydex to be practially silly in terms of risk... In my own use so far of 0.093" kydex it really doesn't seem to be a risk, so I've not yet resorted to aluminum frames.