PTFE Cable Insulation Tape

PTFE Cable Insulation Tape - High Density PTFE Film for Wire & Cable

FOREVERSEAL PTFE Cable Insulation Tape is a high-density expanded PTFE (ePTFE) film engineered for electrical insulation in wire and cable applications. With a standard density of 1.60 g/cm³, thicknesses from 0.051mm to 0.254mm, and widths from 4mm to 200mm, this film provides the inherent properties of PTFE - exceptional chemical resistance, an extremely wide temperature range (-268°C to +260°C), low coefficient of friction, and outstanding dielectric strength - with the added advantage of superior conformability for cable wrapping.

A key feature of this tape is its "sintered in place" capability: the film can be wrapped around a wire or cable bundle and then sintered (heated above 327°C) during the cable manufacturing process, fusing the PTFE into a continuous, seamless insulation layer. This creates a superior seal with no gaps, no joints, and no moisture paths - ideal for high-performance cable insulation, harness wrapping, and as the dielectric medium in coaxial cable construction.

Used primarily in aerospace, military, automotive, telecommunications, and industrial wire applications, this tape prevents short circuits, provides insulation against moisture and contaminants, and reduces friction and wear on moving cable assemblies.

Key Differentiator: At 1.60 g/cm³, this HD PTFE film is significantly denser than our low-density ePTFE film (0.7 g/cm³) - providing higher dielectric strength, better mechanical toughness, and superior performance in high-voltage and high-frequency applications. The "sintered in place" capability further sets it apart: after wrapping, the entire assembly can be sintered to create a monolithic PTFE insulation layer.

 

HD vs. LD PTFE Film - Technical Explainer 

What is High Density (HD) PTFE Film?

PTFE film for wire and cable applications is produced in two primary density categories. Understanding the difference is critical for selecting the right product:

Property	HD PTFE Film (This Product)	LD ePTFE Film (Low Density)
Density	1.60 g/cm³ (high)	0.7 g/cm³ (low)
Structure	Denser expanded, less porous	Highly expanded, microporous
Dielectric Strength	Higher - better for high-voltage	Good - sufficient for general use
Mechanical Toughness	Higher tensile, better abrasion resistance	Softer, more conformable
Conformability	Good - wraps smoothly around cables	Excellent - highly flexible
Sintered in Place	Yes - designed for sintering during assembly	No - not designed for in-place sintering
Best For	Coaxial dielectric, high-voltage insulation, harness wrap	Wire wrapping, abrasion protection, gaskets
Temperature Range	-268°C to +260°C	-190°C to +260°C
Cost	Moderate (higher than LD, lower than skived)	Lower (no sintering step)

· PTFE(Polytetrafluorethylene)

· Expanded, natural or white

· Thickness: 0.051mm - 0.254mm

· Width: 4mm -200mm

· Standard density: 1.60g/cm³

 

 

 

Thickness	0.0020"	0.0030"	0.0040"	0.0050"	0.0060"	0.0080"	0.0100"
	(0.051mm)	(0.076mm)	(0.102mm)	(0.127mm)	(0.152mm)	(0.203mm)	(0.254mm)
Tolerance	±0.00020"	±0.00020"	±0.00025"	±0.00030"	±0.00030"	±0.0004"	±0.00040"
	±0.005mm	±0.005mm	±0.006mm	±0.0076mm	±0.0076mm	±0.010mm	±0.010mm
Width	4 - 200mm
Density	1.6g/cm3
Tensile Strength (minimum)	10 MPa
Elongation (minimum)	50%
Joint Free Lengths	> 200m

 

 

 

FOREVERSEAL HD PTFE Cable Insulation Tape is used across multiple industries where wires and cables require high-performance insulation, dielectric barriers, or friction reduction:

Industry / Application	How PTFE Tape Is Used	Key Property Required
Coaxial Cable Manufacturing	Dielectric wrapping layer between conductor and shield	Consistent dielectric constant, low signal loss
Aerospace Wiring	High-temp insulation for aircraft wiring harnesses	Temperature range, lightweight, sintered-in-place seal
Military & Defense Cables	Insulation for tactical cables, missile wiring, radar cables	Mechanical toughness, chemical resistance, reliability
Automotive Wire Harnesses	Insulation wrap for under-hood high-temp wiring	Temperature resistance, low friction, abrasion resistance
Telecommunications	Insulation for high-frequency signal cables	Low dielectric constant, low dissipation factor
Industrial Cables	Insulation for cables in chemical plants, steel mills, refineries	Chemical inertness, temperature stability
Medical Device Wires	Insulation for catheter wires, sensor leads	Biocompatible, non-toxic, chemical inertness
Sensor & Probe Wires	Insulation for temperature/pressure sensor wires in harsh environments	Chemical resistance, thermal stability
High-Voltage Cables	Insulation layer for HV cable assemblies	High dielectric strength, sintered-in-place seamlessness

 

FAQ：

 

Q: What is HD PTFE cable insulation tape?

A: HD (High Density) PTFE cable insulation tape is an expanded PTFE (ePTFE) film with a density of 1.60 g/cm³, engineered for electrical insulation in wire and cable applications. It is denser than LD ePTFE film (0.7 g/cm³), providing higher dielectric strength and better mechanical toughness. It can also be sintered in place during cable manufacturing.

 

Q: What does "sintered in place" mean?

A: "Sintered in place" means the PTFE film is wrapped around a conductor and then the entire assembly is heated to 370°C–400°C, fusing the PTFE particles into a continuous, seamless insulation layer. This creates a monolithic barrier with no joints or seams - the gold standard for high-performance cable insulation.

 

Q: What is the difference between HD and LD PTFE film?

A: HD film (this product) has a density of 1.60 g/cm³ - denser, with higher dielectric strength and better mechanical properties. It can be sintered in place. LD film (0.7 g/cm³) is softer, more conformable, and less expensive - better for simple wire wrapping and abrasion protection. HD is better for demanding applications like coaxial dielectrics and high-voltage insulation.

 

Q: What thicknesses and widths are available?

A: Thickness ranges from 0.051mm to 0.254mm (0.002" to 0.010"). Widths are custom slit to any dimension from 4mm to 200mm. Contact us with your specifications for a custom quotation.