Mylar Electrical Insulation

Mylar Electrical Insulation

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Material Enquiry

For information on Mylar Electrical Insulation please complete the following quick enquiry or call us on +44(0)1384 252555.

    Characteristics Of Mylar Electrical Insulation

    • Colour: transparent - milky white depending on grade
    • Thickness: 12 - 500 microns
    • Roll size: 914mm wide x 25 to 200mtrs (depending on thickness)
    • Resistances: moisture, solvents, oil and grease
    • Dielectric Strength: 7000 volts/mil
    • Flammability: certain grades offer UL94 VTM-0 flame rating classification and are halogen-free.

    Full technical data can be supplied upon request,
    or downloaded from our online portal.

    What Is Mylar Electrical Insulation?

    At Advanced Seals & Gaskets Ltd, we maintain an extensive inventory of electrical insulation materials, encompassing papers, resins, laminates, and plastics. Among these materials, Mylar, also known as BoPET (Biaxially-oriented polyethylene terephthalate), Melinex, and Hostaphan, stands out. It's a polyester film derived from stretched polyethylene terephthalate (PET).

    Mylar Electrical insulation films are incredibly thin, measured in microns rather than millimeters, with options ranging from 12 to 500 microns. These films are manufactured in roll form, with a width of 914mm and lengths varying from 25 meters up to 200 meters, contingent on the thickness.

    Our rolls of Mylar material can undergo lamination with various adhesive coatings or foils before conversion into final products like pads, gaskets, or washers. Conversion techniques include die-cutting, thermoforming, slitting, and log cutting, producing coils or strips of film or tape. This versatile plastic film finds utility across various general-purpose industrial applications within engineering, chemical, and electrical industries.

    Why Use Mylar Electrical Insulation?

    Mylar films find versatile applications in magnetic media, imaging, graphics, and packaging markets. However, their predominant use is in electronic and electrical applications as insulation materials. Mylar electrical insulation materials possess exceptional aging resistance, strength, flexibility, high tensile strength, durability, and dimensional stability.

    These materials, along with components cut from Mylar raw materials, exhibit low moisture absorption, excellent dielectric properties, and high thermal resistance, effectively withstanding temperatures ranging from -70°C to +150°C. Full-sized rolls of Mylar electrical insulation can be obtained, with lengths varying from 25 to 200 linear meters and widths of 914mm, depending on the thickness (gauge), which ranges from 23 to 500 microns. These rolls are used to create a wide array of finished components and products.

    Benefits Of Using Mylar Electrical Insulation

    • Versatile and durable multipurpose PET plastic film
    • Excellent resistance to water and most chemicals (not alcohol)
    • Operating temperature range of -70°C to +150°C
    • Impact and tear-resistant
    • Electrically insulating
    • Thickness of 23 to 500 microns

    Types Of Electrical Insulation Materials Available

    Advanced Seals & Gaskets collaborates with numerous material manufacturers, offering an extensive selection of electrical insulation materials, catering to diverse applications. Our most favored electrical insulation materials include:

    Epoxy Glass - characterized by a green hue, boasts commendable mechanical strength, excellent chemical, electrical, and radiation resistance, low moisture absorption, and an operational temperature range extending up to +120℃.

    Kapton - a polyamide film that combines remarkable mechanical and tear strength with outstanding chemical, electrical, and thermal properties, making it a resilient choice for vibration-prone and extreme-temperature environments.

    Leatheroid - a grey/blue hued paper gasket material, occasionally referred to as Elephantide, preferred in the electrical industry for insulating high-temperature components.

    MICA - a mineral-based sheet material with superior mechanical performance, resilience to chemicals, and exceptional electrical and thermal insulation properties. MICA gaskets are a preferred alternative to asbestos due to their ability to endure exceedingly high temperatures, reaching up to 1000℃.


    Nomex, available in paper or board form, endures high temperatures, boasting impressive mechanical and dielectric strength, an ideal insulation material for diverse electrical equipment.

    Presspahn, a brown material, crafted from kraft wood pulp, touts outstanding physical and mechanical properties, typically serving as electrical insulation.

    SRBF, a resin-bonded fiber material, combines toughness and rigidity, functioning at temperatures up to 120℃, resisting water absorption, impacts, and chemicals.

    SRBP, built from layers of paper and synthetic resins, proves apt for high and medium-voltage scenarios, offering strong mechanical and exceptional electrical insulation properties, coupled with minimal water absorption.

    Valox, a superb electrical insulator, additionally features flame-retardant properties.

    PTFE, a non-conductive plastic, excels at producing electrical insulation sheets, suitable for high-temperature applications due to its elevated melting point, presenting remarkable dielectric qualities, often employed in circuit boards.

    PVC, a robust, lightweight material, resists abrasion, chemicals, and moisture, boasts solid dielectric strength, rendering it an excellent choice for electrical insulation applications.

    Advantages Of Using Mylar Electrical Insulation

    Mylar stands out as a versatile electrical insulation material, ideal for applications in printing, packaging, sealing, and electrical fields. Its extensive list of commendable qualities includes resistance to moisture and various chemicals, a broad operating temperature range from -70°C to +150°C, effective gas sealing, and exceptional strength, flexibility, durability, and longevity. Mylar electrical insulation comes in various thicknesses, ranging from 23 to 500 microns, and is available in rolls of 25 to 200 meters in length, offering different grades, including a relatively new flame retardant variation.

    The rough surface of Mylar enhances its usability, aiding in handling, conversion, and adhesive attachment before further processing. Mylar Electrical Insulation is supplied in full rolls or cut and provided as sheets, and it is converted into components like pads, gaskets, washers, and strips, all offered with either a plain or self-adhesive finish. Its versatility extends to various applications, with Mylar Electrical Insulation being commonly used in cable insulation, heating elements, solar panels, motors, and aerospace sectors.

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