Choosing an electrical insulation material is not as simple as picking the strongest or most durable option. Every application has different requirements, and the right material depends on how the finished part will be used.
Some projects require a rigid material that can withstand mechanical stress, while others need a flexible material that can be converted into custom die-cut components. Temperature, moisture exposure, electrical performance, fabrication requirements, and the final application all play a role in selecting the best material.
At American Micro Industries, we work with customers across industries including aerospace, defense, electronics, automotive, marine, and medical to manufacture custom electrical insulation components. From CNC machining to die cutting and laser cutting, we help customers select materials that meet both their performance requirements and manufacturing goals.
If you are wondering which electrical insulation material is right for your next project, here are some of the most commonly used options and where each one performs best.
Before selecting a material, it is important to understand what the end use for the component is.
Some projects prioritize electrical resistance, while others require a material that machines cleanly or can be converted into complex die-cut parts. Environmental conditions also matter. Will the component be exposed to moisture? Heat? Mechanical wear? Does it need to maintain its shape over time?
Some of the most important factors to evaluate include:
Answering these questions early helps narrow the list of suitable materials and can prevent unnecessary manufacturing costs later in the project.
G10/FR4 is one of the most widely used electrical insulation materials because it combines excellent electrical properties with outstanding mechanical strength.
Manufactured from woven fiberglass cloth and epoxy resin, G10/FR4 provides a rigid, durable material that performs well in demanding environments. It offers excellent dimensional stability and resists moisture while maintaining its insulating properties.
Because of these characteristics, G10/FR4 is commonly used for electrical components that require both structural strength and reliable electrical insulation.
At American Micro Industries, G10/FR4 is available in sheet form and can be fabricated into custom components using CNC machining. It is important to know the project requirements and material thickness, our team can help determine the best fabrication method for the finished part.
Fish paper has been used in electrical insulation applications for many years and is commonly selected for custom insulation components. Fish paper can provide a practical solution for electrical insulation parts that require precision fabrication, depending on the material thickness and application requirements. The material performance varies by thickness, selecting the right grade is an important part of the design process.
American Micro Industries supplies fish paper in multiple forms, including sheet stock, pressure-sensitive adhesive (PSA) backed material, and fully fabricated parts. Our team can recommend the most appropriate fabrication method for your application based on the material thickness and part design.
Fish paper is commonly selected for projects that require:
American Micro Industries supplies fish paper in sheet stock, pressure-sensitive adhesive (PSA) backed material, and custom fabricated components. Depending on the material thickness and part design, we can recommend the most appropriate fabrication method for your application.
For applications that require a thin, flexible insulation material with dependable long-term performance, polyester film is often an excellent choice.
American Micro Industries offers polyester film materials that provide excellent dimensional stability, moisture resistance, and heat resistance. These characteristics make polyester film well suited for electrical insulation applications where maintaining consistent performance over time is important.
Another advantage of polyester film is its versatility during fabrication. American Micro Industries can manufacture custom components using die cutting, laser cutting, and waterjet cutting to produce parts that meet exact customer specifications.
Polyester film is commonly used when a project requires:
Its combination of durability and flexibility makes polyester film a reliable option for many electrical and industrial applications, especially when precise custom parts are needed for production.
Some electrical insulation applications require a material that can support flexibility, bend lines, and consistent flatness. In these situations, VHR-115 may be a strong option, especially when fish paper is not the best fit for the part design or material thickness.
American Micro Industries offers VHR-115 in sheet form, pressure-sensitive adhesive (PSA) backed material, and custom-fabricated parts. Like many of the company’s insulation materials, it can be converted into precision components using die cutting, laser cutting, and other fabrication methods.
VHR-115 is commonly used in applications such as:
Because VHR-115 can support bend lines and maintain flatness well, it is often considered when the finished part needs flexibility without sacrificing reliable electrical insulation performance.
Rather than trying to make one material work for every application, choosing the material that best matches the performance requirements can lead to better long-term results and a more efficient manufacturing process.
Phenolics are a broad category of reinforced laminate materials used for machined components, electrical insulation applications, and industrial parts. This category includes several material types and grades, the right choice depends on the finished part, application, and fabrication requirements.
LE Phenolic is made from linen cotton cloth with a finer weave than CE phenolic. This gives LE phenolic a better finish and improved machining characteristics, making it suitable for precise components such as panels, terminal strips, ball bearing retainers, and fine gears.
CE Phenolic is made from medium-weave cotton cloth and phenolic resin. It offers good mechanical properties and is commonly used for pulleys, rollers, gears, guides, and electrical insulation control boards.
XX Phenolics include NEMA X-grade through XXX-grade materials. American Micro Industries machines these materials for applications such as gears and gaskets used in aerospace, automotive, and electronic manufacturing.
Garolite® G10/FR4 is one of the most versatile phenolics American Micro Industries works with. It is a fire-resistant glass-reinforced epoxy laminate with strong mechanical properties and dielectric strength in dry, wet, and humid environments.
Other Garolite® Phenolics include G5/G9, G7, G11/FR5, GPO1, and GPO3. These materials may be considered for applications such as switchboard panels, circuit breaker parts, structural electrical components, high-voltage switchgear barriers, supports, panels, and insulators.
Phenolics include many material grades, they should not all be treated the same. Some are better suited for CNC machining, while thin phenolic sheet stock under 0.005 inches may be considered for die cutting. Thicker phenolics are not recommended for steel rule or rotary die cutting because they may crack or splinter, making laser cutting or CNC Machining a better option for certain high-precision or complex components.
American Micro Industries supports clients across manufacturing, automotive, aerospace, military contracting, and other industries. From bulk electrical insulation and sound deadening materials to in-house CNC machining, die cutting, laser cutting, plastic machining, and more, our team can help you find the right solution for your project.
