High Quality Die-Cutting Kapton / Polyimide Film
- Custom die-cut Kapton and polyimide film parts for electrical insulation, masking, and battery assemblies
- Flexible MOQ support for prototype builds, pilot runs, and volume production
- Thin-gauge converting for precise apertures, narrow bridges, insulation tabs, and layered film parts
- Good fit for high-temperature electrical protection, FPC shielding, and compact electronics
- IATF 16949 support and production-minded converting for demanding industrial applications
- Kapton and other polyimide films are known for stable electrical insulation across wide temperature ranges and thin-gauge constructions.
- Many grades maintain dimensional stability, dielectric performance, and mechanical integrity in compact electronics and high-heat environments.
- Polyimide film can be supplied as plain film, adhesive-backed film, release-liner constructions, or laminated multi-layer insulation assemblies.
- It is often selected when the design needs precise die-cut windows, narrow tabs, low-profile barriers, and reliable electrical separation.
- Converted Kapton parts are commonly used in EV battery systems, motors, transformers, FPC assemblies, sensors, and industrial electronics.
| Representative Grade | DuPont Kapton HN, representative reference based on 100HN film, 25.4 um / 1 mil thickness. |
|---|---|
| Standard Thicknesses | 12.7 um, 25.4 um, 50.8 um, 76.2 um, and 127 um are the most widely referenced standard Kapton HN gauges. |
| Service Temperature Range | -269 C to 400 C, with a Relative Thermal Index of 240 C and flammability rated UL 94 V-0. |
| Mechanical Strength | Tensile strength 231 MPa at 23 C, tensile modulus 2.76 GPa, and elongation at break about 72 percent for 100HN. |
| Dielectric Performance | Dielectric strength about 303 kV/mm and dielectric constant about 3.40 at 1 kHz for the 25.4 um reference grade. |
| Thermal Properties | Thermal conductivity about 0.20 W/m-K and coefficient of thermal expansion about 20 ppm/C from 50 C to 200 C. |
| Physical Properties | Density about 1.42 g/cc with moisture absorption near 1.8 percent at equilibrium for standard Kapton HN film. |
We supply die-cut Kapton and polyimide film parts for projects that need both thin profile and dependable insulation performance. Typical uses include battery cell wrapping barriers, busbar isolation layers, FPC protection parts, motor slot insulation, and masking shapes for heat-sensitive processing workflows.
Electronics and Electricals:
Used for dielectric barriers, coil insulation, PCB and FPC protection, and compact insulating spacers where thinness and stability matter.
EV Battery and Energy Storage:
Used in cell-to-cell insulation, busbar barriers, pack protection layers, and module builds that need heat resistance and electrical separation.
Industrial and Aerospace:
Chosen for high-temperature insulating layers, lightweight protection parts, and specialty converted components used in demanding thermal and electrical environments.
Masking and Process Protection:
Adhesive-backed Kapton constructions are often selected for temporary heat-resistant masking, transfer protection, and process control applications.
Kapton is one of the best-known polyimide film brands, but in converting work the bigger issue is usually the final structure rather than the name alone. Engineers often compare base film thickness, adhesive system, liner format, dimensional tolerance, dielectric requirement, and whether the part will be laminated before die cutting.
Because polyimide film is thin and strong, the converting process has to control edge quality, handling marks, static, and part stability carefully. For projects that involve layered insulation or adhesive-backed constructions, we also review liner release, registration, and downstream assembly behavior before recommending the final converted format.
If your team is still comparing Kapton with PET or other insulating films, our electrical isolation solutions page is a useful next step for broader application context.
Kapton / Polyimide Film Formats We Support
Plain film, adhesive-backed film, release-liner constructions, laminated insulation stacks, strip parts, kiss-cut formats, and precision die-cut custom shapes for electronics, battery, and industrial insulation applications.
Custom Die-Cutting Services
for Kapton / Polyimide Film
We supply custom die-cut Kapton and polyimide film parts for electrical isolation, battery pack builds, high-temperature masking, and layered electronics assemblies. Formats can be delivered as individual parts, sheets, strips, or adhesive-backed constructions matched to your assembly flow.
For thin gauges and precise geometries, we focus on liner handling, narrow bridges, aperture accuracy, and repeatable output from prototype through production. When the project is still at geometry-validation stage, we can also discuss laser cutting before the final die-cut route is locked.
Precise Die-Cutting Process
for Kapton / Polyimide Film
Kapton and polyimide film projects usually require more than only shape control. The process also needs to account for film gauge, curl behavior, liner release, adhesive response, and whether the finished part will be hand-placed, automatically fed, or laminated into a larger stack.
Depending on geometry and output format, we may recommend rotary die cutting, flatbed die cutting, kiss cutting, or laminated strip builds. For especially thin insulating parts, we also review static control, waste removal, precision slitting, and package presentation to keep the finished parts clean and stable.
Kapton / Polyimide Film – Our Precision Die-Cutting Solutions
Our Die-Cutting Equipment
Our converting workflow supports thin film handling, liner-based processing, and precision part removal for Kapton and polyimide film programs. This matters when the project needs repeatable apertures, narrow tabs, stable strip presentation, or laminated insulation layers that must stay aligned through downstream assembly.
For projects that also involve layered builds, our multi-layer lamination capability can be combined with die cutting to create more controlled insulation structures before final conversion.
Our Die-Cutting Quality Control
Kapton parts often go into assemblies where the film is thin, the geometry is tight, and the electrical role is critical. That makes edge quality, dimensional repeatability, liner stability, and surface cleanliness more important than they may look in a simple sample review. We inspect converted parts for dimensional conformity, part stability, and usable presentation before shipment.
If the application is focused on electrical barriers, our electrical isolation die-cutting solutions page shows how those converted parts are used in real product structures.
Our Inspection Team
Our inspection team reviews the finished parts in the format customers actually receive, whether that is sheeted parts, liner-backed strips, or laminated assemblies. That helps us confirm not only the shape itself, but also whether the parts can be handled and applied consistently in the customer’s downstream process. For contamination-sensitive builds, we can also review a cleanroom die cutting workflow early in the project.
Our Mold Management
For recurring Kapton programs, tooling control is important because thin film parts can amplify small inconsistencies in edge geometry, release behavior, and waste removal. We review tool design, registration requirements, and production stability together so the converted part can scale cleanly from sample stage to mass production.
Our Product Cases
Typical Kapton product cases include EV battery insulation tabs, FPC reinforcement and protection layers, precision electrical barriers, sensor insulation parts, and high-temperature masking shapes. In these projects, the end-use value usually comes from combining thin profile, temperature resistance, and stable electrical separation in one compact converted component.
Teams comparing Kapton against PET or broader protection materials often also review our insulation and protection solutions and thermal management solutions pages at the same time.
Contact us to customize your Kapton / polyimide film solutions.
Frequently Asked Questions
These are the questions engineers and sourcing teams most often raise when they compare Kapton / polyimide film for insulation, masking, and thin converted parts in electronics and battery programs.
What is Kapton polyimide film mainly used for in die-cut parts?
Kapton polyimide film is mainly used for thin electrical insulation, high-temperature masking, battery barriers, FPC protection, and compact electronics assemblies where the design needs stable dielectric performance in a low-profile converted part.
Is Kapton better than PET or Mylar for high-temperature insulation?
In many high-temperature applications, Kapton or other polyimide films are chosen because they generally tolerate more heat than standard PET-based insulation films. The right choice still depends on electrical requirement, thickness, cost target, and final assembly method.
Can you supply adhesive-backed Kapton parts on liner?
Yes. We can support adhesive-backed Kapton constructions, liner-based strip parts, and laminated insulation builds when the project needs cleaner transfer, easier placement, or a combined protection-and-bonding structure.
What information should I provide for a Kapton die-cutting quote?
It helps to provide the drawing or part size, film thickness, whether adhesive or liner is required, temperature and electrical requirement, target application, and whether the project is for prototype, pilot run, or volume production.
Can Kapton film be used in battery and power electronics assemblies?
Yes. Kapton polyimide film is often used in battery and power electronics assemblies for electrical insulation, high-temperature resistance, and thin barrier protection, especially when the final design needs compact converted parts with precise geometry.
Send Your Inquiry Today
Share your drawing, thickness, adhesive structure, temperature target, and application. We can help review whether Kapton / polyimide film is the right converted format for your project.