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Custom Components for the Electronics Industry

Electrical and Electronics Industry

If you need custom components for the electronics industry, American Micro Industries is your go-to resource. We specialize in manufacturing custom parts, and will identify materials, produce components and ship to you, all from one location. All you have to do is provide us with your specifications. You can also send us parts, drawings or research materials.

We focus on quality and precision and will find innovative ways to meet your project's unique needs. Each piece gets the rigorous attention to detail that has enabled us to work with some of the most renowned electrical and electronics original equipment manufacturers in the world. We serve a wide variety of industries and are continuously expanding our capabilities.

We only use the highest-quality materials to help us maintain our dedication to exceeding our customers' needs. We will go above and beyond to ensure we complete your project successfully, on time and on budget. We take pride in every component we produce.

At American Micro Industries, we are truly your one-stop shop for replacement or new custom electronic components. We would love to work with you, so contact us to learn more . To provide you with more information about the services we offer when it comes to custom electronics industry components, we've created the following guide detailing some of the electrical insulation materials and processes we use.

Electrical Insulation Material Selection

We offer a number of in-stock electrical insulating materials for when you need an electrical insulator with high dielectric strength. We provide sheet, tube and rod stock of materials, including G10/FR4 Phenolics, fish paper, polyester film and VHR-115. We can die-cut and fabricate these substances to your specifications. Learn more about the materials we have available below.

G10/FR4

G10/FR4, which also goes by the names Micarta and Bakelite, is a type of thermosetting glass-reinforced laminate material with an epoxy resin binder. G10 comes in sheets, rods and tubes, and appears in printed circuit boards. It’s made from electrical glass cloth that is alkali-free, to which an epoxy resin is applied using heat and pressure.

g10-Fr4

The FR portion of the name refers to the fact that the substance is a flame retardant. It has an Underwriter Labs 94 (UL 94) flammability classification of 94V-0 and a maximum continuous operating temperature of 285 degrees Fahrenheit. G10/FR4 is well suited to machining and die-cutting. It has superb mechanical properties at moderate humidity, and our die-cut and machined G10 insulators have a 70,000 pound-force per square inch (psi) flexural strength . Other strength-related properties of G10/R4 include:

· Tensile strength: 40,000 psi lengthwise and 35,000 psi crosswise

· Compressive strength: 60,000 psi flatwise and 35,000 psi edgewise

· Shear strength: 19,000 psi

· Bond strength: 2,000 pounds

G10/FR4 has the highest dielectric strength of all of the materials we offer, at 500 volts per mil. A mil equals one one-thousandth of an inch. Its excellent dielectric strength makes it ideal for uses that require a thickness as low as 0.005 inches.

G10/FR4 also has excellent insulation properties, making it useful for various applications. The material holds its structural integrity, even in humidity. You can find G10/FR4 in lighting fixtures, electrical controls, transformers, timers, switches and various other electrical devices and electronic instruments. We can also produce custom die-cut or machined parts for the electronics industry from G10/FR4 to your specifications.

Fish Paper

Fish paper, also written as fishpaper, is a kind of fibrous dielectric paper. Electrical-grade fish paper is vulcanized, meaning it undergoes a chemical process caused by the addition of accelerators or curatives to transform a polymer into a more durable material.

fish paper

This material has an unusual set of characteristics that make it useful for various applications. It is strong, but also lends itself well to forming and punching. Compared to similar plastic materials, it's more resistant to extreme temperatures. Additionally, it has very high tensile strength, resistance to breaking when under tension and good arc resistance. Exact specifications at 0.62 inches thick are as follows:

· Density: 1.2 grams/cubic centimeter

· Tensile strength: 18,000 psi

· Flexural strength: 15,000 psi

· Compressive strength: 35,000 psi

· Izod impact strength: 2.5 ft.-lbs./in notch

· Bond strength: 900 psi

· Mullen bursting strength: 325 psi

· Elmendorf tear strength: 550 grams

· Short-time dielectric strength: 215 volts/mil

Fish paper typically comes in sheets, but might also be sold in coils or rolls designed for automatic punching. This material is ideal for use as an electrical insulation material. Additionally, we can die cut it to make one-off parts for unique applications. Besides its use as electrical insulation, you might find fish paper in electrical instruments, electronic devices, appliances, automotive parts, circuit breakers, fuse tubes, gaskets and more.

Polyester Film

Polyester film is a polymer resin, specifically polymer polyethylene terephthalate (PET), which is extremely versatile and sees use in a wide range of everyday products.

polyester film

Polyester film is both flexible and durable and is highly stable as an insulating material. It has high dielectric and tensile strength. It also has good chemical resistance and can withstand high temperatures, as well as moisture. The material has a UL94 flammability classification of 94VTM-2. Polyester film has the following characteristics :

· Density: 1.39 grams/cubic centimeter

· Machine direction (MD) tensile strength: 28,000 psi

· Transverse direction (TD) tensile strength: 34,000 psi

· AC dielectric strength: 7,000 volts/mil

· Heat resistance: 446 degrees Fahrenheit

You can apply a wide range of treatments to polyester film. It can be stamped, punched, metalized, embossed, corrugated, printed on, dyed and coated.

Dura-Lar®, another kind of polyester film, combines properties of polyester film with acetate. Dura-Lar® has excellent heat resistance, durability and dimensional stability. It can be used as electrical insulation, as well as in other industrial applications.

Polyester film has many various possible uses. Besides being used as an electric insulator, it is also employed in product packaging, as a window film to strengthen glass, in printing, labeling and the manufacturing of medical devices. American Micro Industries can provide polyester film in 20-inch by 50-inch sheets or create custom machined or die-cut parts. We also offer polyester film with and without a pressure-sensitive adhesive, or PSA.

VHR-115

We also offer VHR-115, a multi-ply material made from acrylic polymer and unbleached kraft pulp. VHR-115 has a UL-94 flammability classification of 94HB and a working temperature of up to 230 degrees Fahrenheit.

vhr 115

VHR-115 also offers an excellent dielectric strength of 250 volts per mil and fantastic mechanical strength. Other features include low water absorption, high punchability and high foldability. It is free of chemical impurities, conducting particles and foreign matter, which gives it outstanding aging characteristics in air up to 239 degrees Fahrenheit. This material has the following properties at a thickness of 0.025 inches :

· Weight: 0.136 pounds per square foot

· Average MD tensile strength: 540 pounds per inch

· Average burst strength: 460 pounds per square inch

· Dielectric strength: 250 volts/mil

Because it is highly foldable, VHR-115 is recommended for uses that require creases and fold lines with material thickness that is higher than 0.5 millimeters. It often serves as a substitute for fish paper, because it won't break when folded like fish paper will.

This material can be used in electrical devices, enclosures, transformers, coils, motor components, electrical hardware and other electrical applications that require superior dielectric and physical strength. We provide VHR-115 in sheets and also as custom die-cut components. Our VHR-115 comes in various thicknesses : 0.010 inches, 0.015 inches, 0.020 inches, 0.031 inches and 0.062 inches. We also offer it with or without a PSA.

EMI/FRI Shield Machining

In electronics manufacturing, you need to protect against electromagnetic interference (EMI) and radio frequency interference (RFI), terms that refer to electromagnetic noise and its effect on a component. EMI and RFI shielding are crucial for consumer electronics, aerospace, defense and other manufacturing sectors.

EMI and RFI shielding can prevent a device from creating unwanted inference, protect a device from outside interference and contain or exclude RFI and EMI while pressure-sealing a device and ground an electronic device. American Micro Industries can provide expert fabrication and quality materials to create the shielding capabilities your project requires.

EMI and RFI Shielding Materials

There are many shielding materials, and they each work best in different applications. Some typical materials used for shielding include:

  • Laminate shields use a dielectric base such as PVC or Polyester Film along with an electrically conductive metal layer, such as copper or aluminum foil. Desirable properties of laminates include their light weight, their thinness and their affordability. They can be used in a variety of applications, including consumer electronics and flexible printed circuit boards for use in telecommunications devices.
  • Plastic compounds can also be used as a shielding material. With this option, standard elastomers like silicone and polycarbonate can be infused with carbon or stainless-steel fibers. Plastic shielding is flexible and cost-effective, making it ideal for projects involving irregular designs. Plastic shielding frequently shows up in components such as connector gaskets used in automotive and aerospace systems.
  • Thin metal strips can also provide EMI shielding. These strips might be made of aluminum, copper or pre-tin plated steel. These materials protect against interference across the RF spectrum and also feature excellent conductivity and a high ratio of strength to weight. Metal strips often act as the shielding material in consumer electronics and medical devices.

Custom Components for the Electronics Industry

At American Micro Industries, we can create unique components to your exact specifications. Our extensive in-house manufacturing capabilities have made us a trusted source for custom-made parts.

We produce parts for a variety of industries, including those that require extremely precise and high-quality specifications such as the aerospace, military and automotive manufacturing sectors. The range of materials and production methods we offer enable us to provide a wide range of unique components. In fact, we have a 90 percent acceptance rate for custom specifications.

We use a number of techniques to deliver the perfect solution for your projects' requirements, including:

  • Computer numerical control (CNC) machining employs a computer software program to guide machinery , rather than manual control. It can produce a variety of different kinds of parts for various industries. CNC machining for the electronics industry is precise and can enable mass production of components with extreme consistency.
  • Die cutting uses a specialized instrument called a die to cut thin, flat materials to the required specifications. We use rotary die cutting, steel die cutting and laser die cutting. Rotary die cutting is ideal for components such as gaskets, steel die cutting is especially useful for mass-producing custom parts and the automatic movement of laser cutting is perfect for precise or complex projects that require a high tolerance.
  • Laser cutting is becoming increasingly common due to its ability to produce precise and complex components quickly. The first step in laser cutting involves inputting designs into a software program. A CNC machine will then move the laser along the desired path. Modern equipment can provide accuracy up to 10 micrometers .

Another aspect of our business that has contributed to our success is our dedication to 100 percent customer satisfaction. We use quality materials and precise manufacturing processes to get you the results your project requires. Because we value relationships and communication, our account managers will walk you through the process of acquiring the component or material you need, and be available to answer any questions you may have. We also do not require a minimum order amount, and we have a low fee for custom tooling.

If you need custom components for the electronics industry and are interested in our services or want to learn more about what we offer, request a free quote or more information using our online form. You can even upload your specifications and technical drawings for your project along with your request. Get started today!