Your Guide to the Benefits and Applications of Polyimide PSA Tapes

If your application ha a demanding environment with high temperatures, few pressure sensitive adhesive (PSA) tapes match the performance of polyimide (Kapton®) tapes. Known for their impressive thermal stability, electrical insulation, and resistance to harsh environments, these tapes have become a staple across industries where failure is not an option. Often referred to by the well-known brand name Kapton® tape, polyimide pressure-sensitive adhesive (PSA) tapes combine robust material science with adhesive versatility to meet the toughest design and manufacturing demands. 

What are Polyimide Tapes?

Polyimide tape is a high-performance adhesive tape made by coating a thin polyimide film with a high-temperature pressure-sensitive adhesive, most commonly silicone. It is engineered for applications that require thermal endurance, electrical insulation, and chemical resistance in extreme or dynamic conditions. 

Originally developed for aerospace use, polyimide tape has since expanded into electronics manufacturing, automotive, medical device production, industrial processes, and defense systems. Its resilience under mechanical, thermal, and chemical stress makes it ideal for both temporary masking and permanent bonding in high-precision assemblies. 

Polyimide Tape Offer Many Benefits

Polyimide tapes are valued for their unique combination of mechanical and chemical properties: 

  • Thermal stability up to 260°C (500°F) or higher 

  • Dielectric strength, making them ideal for electrical insulation 

  • Chemical and solvent resistance, even under high temperatures 

  • Dimensional stability, with minimal shrinkage or expansion during heat cycling 

  • Non-flammability, with many variants rated UL 94V-0 

  • Low outgassing, suitable for vacuum and space applications 

Polyimide tapes are available in several construction types, depending on the demands of the application. Single-sided Polyimide film has an adhesive on one side. It’s most common for insulation or masking. There are also double-sided tapes where the adhesive is applied to both sides of the film, which is useful for bonding or splicing applications. 

As far as adhesive types, most polyimide tapes are offered with: 

  • Silicone Adhesive: offers clean removability and high temperature resistance. This is the most common adhesive system for polyimide tapes. 

  • Acrylic Adhesive: provides stronger initial tack and better adhesion to low surface energy (LSE) substrates like certain plastics or composites. 

There are also reinforced and laminated variants like fiberglass-reinforced polyimide tapes, which have improved tensile strength and tear resistance. Some EMI-shielded polyimide tapes incorporate conductive layers or metallization for grounding and electromagnetic shielding. 

These PSA tapes are available in: 

  • Rolls 

  • Sheets 

  • Die-cut components 

  • Masking dots or tabbing tapes for automated assembly lines 

Polyimide Tapes Offer High Thermal and Electrical Performance

Polyimide tape is particularly well-suited for demanding thermal and electrical environments because of their: 

  • Temperature range: operates from –269°C to +260°C (–452°F to 500°F) depending on construction 

  • Thermal cycling resistance: performs reliably through repeated heat up/cool down processes 

  • Dielectric strength: typically >6,000 V/mil, making it ideal for PCB insulation, motor windings, and coil wraps 

  • Flame resistance: many versions meet UL 94V-0 flame retardancy standards 

These capabilities make polyimide tapes an essential material in high-voltage, high-temperature, and high-precision environments. 

The Common Applications of Polyimide PSA Tapes

Electronics Manufacturing

Polyimide tapes are a standard in PCB assembly and component protection. They’re used for: 

  • Wave solder masking 

  • Insulating and wrapping coils and transformers 

  • Protecting gold fingers during reflow soldering 

  • Splicing flexible circuits 

  • Thermal shielding during component placement and rework 

Their non-conductive and thermal-resistant nature helps ensure assemblies remain protected during harsh production processes. 

Aerospace and Defense

In high-stress and harsh environments like aviation, polyimide tapes are used for: 

  • Wire harness wrapping and cable bundling 

  • Thermal insulation of avionics 

  • Surface masking for chemical etching or anodizing 

  • Space-grade insulation due to low outgassing properties 

Automotive and EV Applications

In automotive and electric vehicle systems, polyimide tapes insulate and protect high-temperature components, including: 

  • Battery cell packs and busbars 

  • Sensor leads in engine compartments 

  • Wire harnesses exposed to heat, vibration, and oil 

Their combination of electrical and chemical resistance makes them ideal for the modern automotive powertrain. 

Industrial Manufacturing

In high-heat industrial processes, polyimide tapes provide reliable performance for: 

  • Masking during powder coating, plasma spraying, or anodizing 

  • Splicing heat-resistant materials 

  • Holding and mounting heater elements, thermocouples, and sensors 

They are also used in 3D printing, semiconductor production, and metal plating. 

Medical Device Manufacturing

Polyimide tapes can be used in sterilization environments, such as autoclaves, due to their heat resistance and low residue: 

  • Insulation for diagnostic sensors 

  • Protective masking during laser cutting or welding 

  • Dielectric layers in electronic monitoring devices 

Polyimide Tape Work in Harsh Industrial Environments

One of the defining features of polyimide tapes is their clean removability. Even after extended exposure to extreme temperatures, these tapes typically peel away cleanly from substrates without leaving behind adhesive residue or causing surface damage. This is especially important in electronics and aerospace manufacturing, where contamination can compromise the performance or appearance of components. 

Polyimide tapes can also maintain their adhesive strength and structural integrity across a remarkably wide temperature range, from low temps to sustained exposure above 260°C (500°F). Unlike other tapes that may shrink, delaminate, or lose adhesion when subjected to high heat or rapid temperature cycling, polyimide tapes continue to perform reliably, even in harsh soldering, reflow, or autoclave processes. 

In addition to thermal resilience, polyimide tapes exhibit chemical inertness, allowing them to resist degradation when exposed to acids, solvents, fuels, cleaning agents, and other aggressive chemicals. This makes them suitable for environments where frequent cleaning, sterilization, or chemical exposure is expected. 

Polyimide’s dimensional integrity also plays a critical role in high-precision applications. The film does not stretch, creep, or warp significantly under stress, vacuum, or compression, making it ideal for applications that require exact fit, alignment, or repeatable performance. 

Finally, the electrical insulating capabilities of polyimide film are superior to many other high-temperature materials. It boasts high dielectric strength, making it a top choice for insulating transformers, motors, and PCB components. Certain constructions also incorporate conductive or metallized layers for EMI shielding, combining electrical insulation and interference protection in a single product. 

How Does Polyimide Compare to Other High-Temperature Tapes

  • Polyimide vs. Polyester (PET): while polyester tapes are less expensive, they degrade at lower temperatures and have somewhat less chemical resistance. 

  • Polyimide vs. Glass Cloth Tape: glass cloth is more durable and heat-resistant in some structural applications, but it is bulkier and less conformable than thin polyimide film. 

  • Polyimide vs. PTFE (Teflon®) Tape: PTFE tapes are prized for their non-stick properties and chemical resistance, but polyimide offers superior electrical insulation and heat stability. 

Considerations When Selecting a Polyimide Tape

At Engineered Materials, we’re here to help you select the right polyimide tape and make sure it’s aligned to your application’s requirements, including: 

  • Temperature exposure: consider both peak and continuous operating temperatures. 

  • Adhesive performance: will the tape need to be repositioned or removed cleanly? 

  • Electrical or EMI protection: do you need insulation, grounding, or shielding capabilities? 

  • Substrate compatibility: ensure the adhesive bonds well to metal, plastic, ceramic, or flex circuits. 

  • Regulatory compliance: look for certifications like RoHS, REACH, UL, or NASA-grade materials for aerospace. 

Need help choosing the right polyimide tape for your application? Contact us today to discuss custom tape solutions, die-cut components, and sourcing options tailored to your project needs. 

Matt Tempelis