Ethyl tert-butyl malonate (CAS NO.: ), which is also known as , tert-butyl ethyl ester, could be produced through the following synthetic routes.

A 2-l. three-necked flask, equipped with a sealed stirrer, a dropping funnel and a reflux condenser provided with a calcium chloride drying tube, is charged with 100 g. (0.625 mole) of diethyl malonate and 400 ml. of commercial absolute ethanol. Stirring is started, and a solution of 35 g. of potassium hydroxide pellets in 400 ml. of commercial absolute ethanol is added at room temperature during a period of 1 hour. A white crystalline precipitate forms during the addition, and, after all the hydroxide has been added, stirring is continued for an additional 2 hours. After the mixture has stood overnight, it is heated to boiling on the steam bath and filtered while hot with suction. Precipitation of the potassium ethyl malonate is completed by cooling the filtrate in an ice bath. The salt is collected by suction filtration, washed with a small amount of ether, and dried under reduced pressure at room temperature. An additional amount of the potassium salt is obtained by concentrating the mother liquors on the steam bath to about 100–125 ml. The total yield is 80–87 g. (75–82%).

A 250-ml. three-necked flask provided with a stirrer, a dropping funnel, and a thermometer is charged with 80 g. (0.470 mole) of potassium ethyl malonate and 50 ml. of water. The mixture is cooled to 5° with an ice bath, and 40 ml. of concentrated hydrochloric acid is added over a 30-minute period while the temperature is maintained below 10°. The mixture is filtered with suction, and the precipitate of potassium chloride washed with 75 ml. of ether. The aqueous layer of the filtrate is separated and washed with three 50-ml. portions of ether. The combined ether solutions are dried over anhydrous magnesium sulfate; then most of the solvent is removed by distillation at atmospheric pressure, and the remainder under reduced pressure. Finally, the liquid residue of monoethyl malonate is dried at 50°/1 mm. for 1 hour. The yield is 58–62 g. (93–100%).

A 500-ml. Pyrex heavy-walled, narrow-mouthed pressure bottle is charged with 100 ml. of ether and 3.5 ml. of concentrated sulfuric acid. The solution is cooled with an ice bath to 5°, and 56 g. (0.42 mole) of monoethyl malonate and approximately 60 ml. (about 0.75 mole) of isobutylene are added. The bottle is immediately closed with a rubber stopper, which is clamped or wired in place, and is shaken mechanically at room temperature overnight. The bottle is chilled in an ice-salt bath and then opened. The reaction mixture is poured into a 1-l. Erlenmeyer flask containing a cooled solution of 50 g. of sodium hydroxide in 200 ml. of water and 200 g. of ice. The mixture is swirled a few times and then transferred to a separatory funnel. The layers are separated, and the aqueous portion is extracted with two 75-ml. portions of ether. The organic layers are combined and dried over anhydrous magnesium sulfate. The solution is concentrated in a 125-ml. round-bottomed flask and distilled at reduced pressure through a 10-cm. Vigreux column. The fraction distilling at 98–100°/22 mm. or 107–109°/24 mm. is collected. The yield is 42–47 g. (53–58%), n_D25 1.4128, n_D23 1.4142.