Marian manufactures custom electrical insulators by die-cutting thin, flexible, electrically insulating materials such as plastic films, rubber, fibers, and papers. These materials include Kapton® polyimide films, Mylar® PET film, ITW Formex® (polypropylene), Nomex® aramid fiber, insulation papers (aka fish paper), Teflon® PTFE, solid rubber sheets such as silicone, neoprene, and many more. Marian can provide these electrical insulators with or without adhesive backing (PSA).
Insulators are designed to prohibit the flow of electric current along unintended paths within and beyond the electrical equipment or device. Insulators preserve the designed function of the electrical component while protecting adjacent components, devices, and users (people).
Dielectric Strength: A Key Property
Dielectric strength is the maximum electric field / electric voltage required to produce an electrical breakdown through a material. The higher the dielectric strength, the higher the material’s resistance to the flow of current. Dielectric strength is a key characteristic for materials used to design electrical insulators.
Ultra-thin and Lightweight
Many electrical insulating materials converted by Marian are ultra-thin and lightweight, while also maintaining excellent electrically insulating properties. This makes them ideal for today’s electronic devices as they become smaller, thinner, and lighter.
Additional Physical and Mechanical Properties
The electrical resistivity and dielectric strength varies among the wide variety of materials listed above and below. Each material provides insulation along with other important performance characteristics such as: flexibility, rigidity, flame retardant, extreme temperature resistance, moisture and chemical resistance, and more. Many materials are also RoHS compliant and UL 94 V-0 rated.
Commonly Die-cut Electrical Insulator Materials
- ITW Formex® polypropylene
- Fish paper / insulation papers
- Nomex® aramid fiber
- Mica insulation papers
- Kapton® polyimide film
- Mylar® polyester film
- Lexan® polycarbonate film
- Melinex® polyester film
- Teflon® PTFE
- Rubber sheets
- Solid silicone rubber
Material Properties Chart
The materials in this chart are a few commonly converted by Marian. Please note that this is a very small representation of the thousands of materials in a wide range of thicknesses that we can choose from. Contact us for help with your material selection.
Markets + Applications
- Electronic devices
- Servers and personal computers
- Power supplies, transformers, inverters
- Battery / electronic vehicle:
- EV Battery busbar insulation
- EV on-board charger insulation
- Insulation between battery cells
- Lighting assemblies
- Aerospace systems
- Military / Defense
- Automotive electronics
- Medical devices
- Marine electronics
Marian’s Manufacturing Techniques
We manufacture custom electrical insulators by means of die-cutting, water jet cutting, and laser cutting. We can also provide secondary operations including scoring, creasing, bending, folding, embossing, screen printing, and pressure sensitive adhesive lamination to meet your requirements.
Work with Marian
Marian maintains close partnerships with top suppliers of engineered insulator materials. After understanding the thermal, electrical and mechanical requirements of your application, your Marian sales engineer can recommend the most suitable materials. Material samples and prototypes can be provided quickly for testing.