What is Mylar tape used for?

In today’s modern industrial and electronic manufacturing fields, polyester film tape has become an indispensable material due to its excellent performance and wide range of applications. Next, we will take a closer look at the uses of mylar tapes and the important role they play in various industries.

What is Mylar Tape?

Mylar tapes are specialty tapes that use polyester film (PET) as the base material and are coated with high-performance pressure-sensitive adhesives, such as acrylic glue or silicone rubber. It is resistant to high temperatures from 130°C to 300°C, and has excellent electrical insulation, chemical resistance and high mechanical strength. Mylar tapes are widely used in scenarios such as electronic circuit shielding, high-temperature component fixing, aviation equipment insulation, and industrial powder coating shielding. In addition, the tape peels off cleanly after use, leaving no adhesive residue.

Why are mylar tapes the ultimate electrical insulator?

Mylar tape can be excellent electrical insulators due to several key factors:

• Excellent electrical insulating properties: Mylar tapes have a high dielectric strength and a rated voltage of ≥ 6kV/mm (UL 510 compliant), which can effectively prevent current leakage and ensure the safe and stable operation of the electrical system.
• Wide temperature adaptability: It can withstand extreme temperatures from -70°C to 150°C and even 200°C for short periods of time. In these extreme temperature environments, mylar tapes remain insulating.
• Excellent mechanical strength: This tape has certain tensile, tear and puncture resistance, can withstand certain external forces, and is not prone to breakage. This makes it possible to effectively protect the encased object from mechanical damage.
• Good chemical resistance: Mylar tapes are highly resistant to a wide range of chemicals and are not susceptible to chemical corrosion. Even in the presence of chemicals, it can maintain its performance stably.
• Clean peel properties: Mylar tape peel clean and leave no adhesive residue after use, reducing maintenance costs and the risk of potential contamination of the object.
• In view of the above characteristics, mylar tape has become the first choice of electrical insulation materials in key application scenarios such as interlayer isolation of motor windings and protection of high-voltage cable joints.

What is Mylar tape used for?

Mylar tape are used in a number of key applications due to their high strength, temperature resistance and insulation:

1. Electronics industry

• Circuit board protection: high temperature resistance (260°C reflow soldering), insulation (withstand voltage≥6kV/mm)
• Screen lamination: high light transmittance (>90%), no adhesive residue (mobile phone/tablet assembly)
• Lithium battery packaging: electrolyte corrosion resistance, insulation protection

2. Automobile manufacturing

• Harness fixing: high temperature resistance (150°C), flame retardant (UL94 V-0)
• Shock and noise reduction: damping tape reduces abnormal noise in the car (tanδ>0.1)

3. Aerospace

• Composite positioning: Viscosity remains at ultra-low temperatures (-196°C).
• Fixed thermal protection layer: short-term temperature resistance 2000°C (rocket engine compartment)

4. Medical equipment

• Sterilized packaging: sterilized by EO (residual < 25 μg/cm²)
• Medical Electrode Fixation: Biocompatible (ISO 10993 certified)

5. Everyday application

• Label substrate: strong weather resistance (outdoor logo does not fade for 10 years)
• Temporary repairs: high viscosity (e.g. pipe sealing)

How Does Mylar Dominate Aerospace Bonding?

The core technical advantages of Mylar in the field of aerospace bonding are reflected in the following aspects:

1. Adaptability to extreme environments

(1) Ultra-vacuum performance
Outgassing rate<1×10⁻⁶ Torr· L/s (NASA ASTM E595 standard)
Mass loss (TML) < 0.1%, volatile condensate (CVCM) < 0.01%
Verification of long-term (10 years) service of extravehicular equipment on the International Space Station

(2) Radiation resistance
γ radiation tolerance>100kGy (equivalent to 15-year cumulative dose of LEO satellites)
Tensile strength retention rate > 90% after 1000 hours of UV irradiation
Combined electron/proton irradiation assay (ESA ECSS-Q-ST-70-02C)

2. Structural engineering solutions

(1) Composite assembly
Carbon fiber skin pre-fixation: VHB™ adhesive provides 8-12N/cm peel strength
Temporary positioning in the automated tape laying process (ATL): -54°C~121°C operating window
Dimensional stability during curing (coefficient of thermal expansion CTE<20ppm/°C)

(2) Thermal Protection System (TPS)
Gap Filling Tape: Ceramic Microsphere Modification System
2000°C oxyacetylene flame test:
Elevated back temperature < 150°C (5 sec exposure)
Self-sealing properties of the carbonized layerSpace Shuttle RCC panel edge sealing application case

3. Special function modification

(1) Conductive variants
Surface resistance 10³-10⁵Ω/sq (anti-static treatment)
Mars rover solar sail panel tandem application

(2) Optical-grade applications
Visible light transmittance>90% (in-cabin display optical bonding)
Solar reflectivity>95% (thermally controlled multilayer insulation)

4. Advantages of the certification system

At the same time, it satisfies the
NASA MSFC-SPEC-1443
ESA ECSS-Q-70-71
Chinese GJB 2549A-2012
Batch consistency control: the key parameter Cpk>1.67
Typical Cases:
Boeing 787 fuselage composite mold positioning
SpaceX Dragon Door Seals
Thermal control layer of the Chang’e-5 lunar sampling facility

Future Breakthrough Directions:
◉ -200°C~300°C wide temperature range tape for deep space exploration
◉ Self-sensing intelligent bonding system (strain/temperature monitoring)
◉ Atomic oxygen protective coating integration technology (LEO environment)
Through continuous material innovation and rigorous aerospace-grade verification, Mylar has built a full-scene adhesive solution system from low earth orbit to deep space exploration, and its technical barriers are mainly reflected in the extreme environment simulation test database and special formula development capabilities.

Why Do Photovoltaic Modules Rely on Mylar?

PV modules rely on Mylar primarily for its superior performance:

Enhanced sunlight reflection:

Mylar has a reflectivity of >95% in the full spectrum range of 300-2500nm, which helps to optimize the optical performance of PV modules, improve the efficiency of solar energy utilization by effectively reflecting light, thereby increasing the power generation capacity of PV modules.

Anti-PID Performance:

Mylar has excellent resistance to potential induced degradation (PID) with a potential induced degradation rate of <2%/1000h. This means that Mylar is able to maintain stable performance over a long period of time, reducing the degradation of power generation efficiency due to the PID effect and extending the service life of PV modules.

Encapsulation Protection Process:

Backsheet Seam Sealing: Mylar is used for backsheet seam sealing of PV modules, with a water vapor transmission rate of <0.1g/m²/day. This feature ensures a dry environment inside the PV module, preventing performance degradation and damage caused by water vapor intrusion, and improving the reliability and durability of the PV module.

Cell positioning accuracy:

Taking the 3M™ 466 model as an example, Mylar is able to achieve a cell positioning accuracy of ±0.2mm. High-precision positioning helps to ensure a good connection between cells, reduces resistance losses, and improves the power generation efficiency of photovoltaic modules.

Which Medical Devices Utilize Mylar’s Biocompatibility?

The biocompatibility of Mylar (polyester film) in medical devices is mainly reflected in the following aspects:

1. Sterilizable packaging

• Ethylene Oxide (EO) Sterilization Compatibility: Mylar is EO sterilization resistant with a residue of <25μg/cm² (ISO 10993-7 compliant) for aseptic packaging of high-value consumables such as surgical instruments and catheters.
• Antibacterial performance: Meets ASTM F1608 standard, with an antibacterial rate of >99.99%, ensuring sterility safety for long-term storage.

2. Implant device marking and identification

• Biocompatibility certification: ISO 10993-5 cytotoxicity tested to ensure no adverse effects (e.g., artificial joints, pacemaker labels) for long-term implantation.
• X-ray/ultrasound enhancement: Contains a 20-50 μm barium compound layer for clear positioning in images (e.g., vascular stents, surgical navigation markers).

3. In vitro diagnostic equipment

• Biosensor substrates: used in blood glucose test strips, PCR microarrays, with an inert surface that avoids sample contamination (ISO 10993-10 skin irritation test).

4. Surgical ancillary materials

• Insulation layer of electrosurgical equipment: high temperature resistance (200°C) and dielectric strength ≥6kV/mm to prevent intraoperative current leakage.

5. Tissue Engineering & Restoration

• Temporary cell culture scaffolds: surface modifications promote cell adhesion (e.g., skin repair membranes) and degradation products meet ISO 10993-13 resorbability.

How Does Mylar Revolutionize Food Packaging?

Mylar has completely reconstructed the technical standards and application scenarios of the food packaging industry through breakthroughs in material science and intelligent upgrades:

1.Revolutionary barrier performance

Ultra-high oxygen barrier

Oxygen permeability <0.5 cm³/m²/day (23°C/0%RH), which is 1/200 of traditional PE film
Multi-layer co-extrusion structure (PET/AlOx/SiOx) extends the shelf life of coffee/nuts to 18 months

Grease and moisture defense

Passed ASTM F119 standard test (72 hours of fried food packaging without leakage)
Water vapor permeability <0.1 g/m²/day (key indicator for chocolate moisture resistance)

Antibacterial active protection

Surface grafted silver ion (Ag⁺) coating, the total number of colonies is reduced by 99.9% (GB 4789.2 verification)

2. Intelligent packaging innovation

Technology type	Implementation method	Application case
Conductive sensing	Printed carbon nanotube circuit (10-100Ω/sq)	Freshness detection (resistance change reflects CO₂ concentration)
TTI label	Thermochromic ink + PET substrate	Vaccine cold chain monitoring (color mutation indicates overtemperature)
RFID fusion	Ultra-thin (25μm) PET antenna substrate	Fresh food traceability (reading distance increased to 3 meters)

What Makes Mylar Tape Ideal for Acoustic Damping?

The reason why mylar tape (PET tape) is an ideal sound insulation material is that it has achieved multiple breakthroughs in vibration suppression and noise control through material property optimization and engineering structure design:

1. Physical mechanism of vibration suppression

High modulus reinforcement

The Young’s modulus ≥ 4 GPa (200 times that of ordinary rubber) can significantly improve the rigidity of components such as speaker diaphragms:

• Move the resonance frequency up by 30-50Hz (at 0.05mm thickness)
• Suppresses “split vibration” distortion at mid to high frequencies (500-5000Hz).

2.Optimized damping performance

The loss factor tanδ>0.1 (critical noise band 1k-5kHz) via:

• Dispersion of silica particles in an acrylic adhesive layer (to improve internal friction)

Multi-layer PET/adhesive alternating structure (widening the effective frequency band)

2. Broadband noise control application

Application scenario	Solution	Test results
Automotive interior	Sheet metal-plastic joint attachment (0.1mm tape)	Abnormal noise reduced by 15dB (SAE J1400 test)
Industrial equipment	Motor housing shock absorption layer	200Hz resonance peak attenuation 40%
Consumer electronics	Mobile phone speaker edge sealing	Mid-frequency harmonic distortion reduced by 8dB

3. Advantages of material properties

Frequency adaptability

By adjusting the crystallinity of PET (30-50%), stable damping is maintained in the range of 10-2000Hz
Temperature stability (-40°C~120°C) ensures that the performance does not decay under severe cold/high temperature conditions

Lightweight design

The areal density is only 35g/m² (0.05mm thick), which is 80% lighter than traditional asphalt damping sheets.
Suitable for noise reduction in aerospace cabins (e.g. helicopter rotor cabin sound insulation)

Composite function integration

Conductive type: surface resistance 10³-10⁶Ω/sq (simultaneous solution to EMI shielding)
Flame retardant type: UL94 V-0 certification (electric vehicle battery pack sound insulation and fire protection)

Why Is Mylar Critical in Cryogenic Environments?

Mylar is critical in low-temperature environments, mainly due to its superior performance at ultra-low temperatures and critical applications in high-tech fields such as superconducting devices and quantum computing devices.

1. Excellent performance in low temperature environment

Ultra-low temperature adhesion performance:
Under the liquid nitrogen immersion test (-196°C), the peel strength retention rate of polyester film can still exceed 80%. This means that the adhesive properties of the polyester film remain stable and reliable even at extremely low temperatures, and will not fail due to sudden temperature drops.
Low thermal shrinkage:
In a gradient test from room temperature to -269°C, the thermal shrinkage of the polyester film is less than 0.5%. This feature ensures that the polyester film can remain dimensionally stable at low temperatures, avoiding performance changes or damage caused by thermal expansion and contraction.

2. Key applications in the high-tech field

Superconducting Device Applications:
In superconducting devices, such as magnet coil interlayer insulation, mylar film is able to withstand strong magnetic fields of more than 20T. Its excellent insulation properties and mechanical strength provide a strong guarantee for the stable operation of superconducting equipment.
Quantum Computing Device Vacuum Sealing:
Mylar is also used for vacuum sealing of quantum computing devices. Its low air permeability and excellent sealing performance help maintain a high vacuum environment inside quantum computing devices, reduce external interference, and improve the operation accuracy and stability of the equipment.

How Do Artists Exploit Mylar’s Optical Properties?

The artist uses the optical properties of polyester film to achieve innovative applications in the two major fields of holographic art creation and cultural relics protection and restoration, as follows:

Holographic art creation

1.High-precision surface properties:

The surface roughness of the polyester film is extremely low (Ra <0.01 μm), which provides ideal precision for laser interference. Artists can take advantage of this property to create extremely detailed and complex holographic patterns on polyester film using laser interference technology.

2.Multi-Layer Coating Reflection:

The polyester film is coated with multiple layers and has an extremely high reflectivity (>99.8%) in the visible light range. This high reflectivity makes the holographic pattern brighter and clearer, enhancing the visual effect and ornamentation of the holographic artwork.

Cultural relics protection and restoration

1.Temporary Reinforcement of Fragile Documents:

Mylar has the characteristics of reversible bonding, and its peeling force is controlled between 0.5-1N/cm. This makes it an ideal material for temporary reinforcement of fragile documents. Artists or conservators can use mylar film to gently stick to the surface of a delicate document to provide additional support and protection, while ensuring that it can be easily peeled off when needed without damaging the document.

2.Ultraviolet filtration:
Mylar has an extremely high blocking rate of UV rays (> 99% @ below 380nm). This feature is particularly important in the conservation and restoration of cultural relics. Ultraviolet rays are one of the main factors that cause the fading and aging of cultural relics. The use of polyester film as a protective material can effectively block the damage of ultraviolet rays to cultural relics and prolong the preservation life of cultural relics.

Conclusion

With its versatility, adaptability and environmental friendliness, mylar tape has become an indispensable material across industries. From precision electronics to heavy industry, from daily packaging to space exploration, its application potential continues to expand, providing solid support for technological innovation and industrial upgrading. In the future, with the advancement of materials science, mylar tape is expected to demonstrate its unique value in more fields.

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This article was written by various LS contributors. LS is a leading resource on manufacturing with CNC machining, sheet metal fabrication, 3D printing, injection molding,metal stamping and more.