What is Mylar®? Definition, Properties, and Uses

Mylar® is a polyester film that is widely used due to its exceptional mechanical and chemical properties. It is so popular that it has become nearly synonymous with any plastic film. Mylar is used in numerous applications, from helium-filled balloons and food packaging to electrical and thermal insulators. It was first developed in the mid-s by the companies Imperial Chemical Industries (ICI), Hoechstand, and DuPont. It is a registered trademark of DuPont Teijin Films. This article will define Mylar film, describe how it&#;s made, discuss its properties, and give examples of Mylar applications.

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What Is Mylar?

Mylar is a plastic film that is coveted for its useful properties, including: chemical and dimensional stability, electrical insulation, impermeability, high tensile strength, reflectivity, and transparency. While the term Mylar is often used to describe any plastic film, it&#;s not the only PET film produced by DuPont Teijin Films. Trade names for other popular PET films include Melinex® and Hostaphan®. 

What Is Mylar Made Of?

Mylar is a polyester film made from polyethylene terephthalate (PET). The material is also known by its scientific name BoPET (biaxially-oriented polyethylene terephthalate). The Mylar fabrication process is described below:

1. PET polymer is melted and extruded onto a chilled drum roller to form a film.
2. The film is stretched biaxially, in the machine (or feed) direction, and in the transverse (width) direction. This is achieved by feeding the film over a series of rollers and then into a stenter frame where it is stretched in the transverse direction. This stretching process serves to orient the PET molecules in such a way as to enhance the film&#;s mechanical properties.
3. The film is heated to 200°C (392°F) to stabilize its structure and to ensure that it does not shrink at temperatures below the original heat set temperature.

At the end of the fabrication process, the Mylar film is so smooth that it tends to stick to itself. Mylar material is often coated with silicon dioxide (SiO2) to reduce stickiness. Additionally, Mylar can be coated with evaporated gold, aluminum, or other metal using a physical vapor deposition process to reduce transparency, increase reflectivity, and make it less permeable to gases. 

What Are the Properties of Mylar?

The versatile properties of Mylar, and its ability to retain its properties across a wide temperature range (-94°F to 302°F or -70°C to 150°C), make it ideal for a variety of applications across different industries. Mylar can be used in extremely low and high temperatures (-418-392°F, or -250-200°C) as long as mechanical requirements are not too demanding. Extreme temperatures can cause degradation of Mylar&#;s tensile strength and ductility. The properties of Mylar are listed below:

1. Tensile strength of 29 ksi
2. Dimensionally stable over a wide temperature range
3. Chemically inert, resistant to oils, solvents, moisture, and grease
4. Low permeability&#;can be used as a barrier against most liquids and gasses 
5. Excellent thermal stability and a low thermal expansion coefficient of 1.7 × 10 &#;5 in/in/°C (9.5 × 10 &#;6 in/in/°F). This makes the material an excellent thermal insulator
6. High electrical resistivity of ohm&#;cm, making it an excellent electrical insulator
7. Reflective. If coated with metallic particles, its reflectivity contributes to thermal stability and aesthetic appeal
8. If not coated, Mylar is transparent and can transmit 80-90% of radiation in visible and infrared spectrums. This can be desired for certain applications such as tags, and equipment labels

What Are the Uses of Mylar?

Mylar has many unique properties that make its use common in numerous applications. Its strength and dimensional stability over a wide temperature range make it a versatile material. Its low permeability makes it great for food packaging, while its electrical properties make it a great electrical insulator. Figure 1 below is an example of a Mylar packaging containers:

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Raw material sizes:

Master roll (by width)

Stock

• .002&#; Silver, 27&#; & 54&#;
• .005&#; Silver, 27&#; & 54&#;
• .002&#; Gold, 54&#;
• .002&#; Brushed, 24&#;

Custom order materials:

• .001&#;-.007&#; Silver Mirror, 20&#;-60&#;
• .001&#;-.007&#; Gold Mirror, 20&#;-60&#;
• .001&#;-.007&#; Colored Mirror, 20&#;-60&#;

Finished Goods stock sizes:

Type27" x 12'27" x 25'27" x 50'27" x 100'54" x 12'54" x 25'54" x 50'54" x 100' Rolls Gold.002"/50um&#;&#;&#;&#; Silver.002"/50um&#;&#;&#;&#;&#;&#;&#;&#; .005"/125um&#;&#;&#;&#; Sheets20" x 27"27" x 40" Gold.002"/50um&#;&#; Silver.002"/50um&#;&#; .005"/125um&#;&#; Packs
9"x12"10"x12" Gold
.002"/50um&#;&#; Silver.002"/50um&#;&#; .005"/125um&#;&#;
Don&#;t see a size that you need? All our ClearLay products can be slit to width, rolled to length, or cut to size. Check out our extensive

Don&#;t see a size that you need? All our ClearLay products can be slit to width, rolled to length, or cut to size. Check out our extensive converting services pages for a full range of converting options for our Clearlay products.

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