What Thickness Options Are Common For Metalized PET Film?
Metalized PET Film is a PET base film coated with a thin vacuum-deposited metal layer, typically aluminum, to enhance barrier performance, reflectivity, and appearance. One of the first specifications buyers confirm is thickness, because it influences stiffness, converting efficiency, barrier consistency, heat management, and how the film behaves during lamination, printing, or winding. While “the best thickness” depends on the end-use structure, there are several thickness ranges that show up repeatedly across packaging, insulation, and industrial laminates.
This article explains the most common thickness options for metalized pet film, how to select them, and what questions to ask when sourcing. For material details and product configurations, browse BIYT metalized PET film.
Typical Thickness Ranges You Will See In The Market
Most metalized pet film is specified in microns. The PET base film thickness is the main variable; the metal layer is extremely thin and generally does not change the overall gauge in a meaningful way for ordering.
Common market ranges:
8–12 μm: lightweight, high yield, flexible webs
12–25 μm: the mainstream range for many laminations and printing structures
25–50 μm: higher stiffness, improved handling, and better dimensional stability
50–100 μm: specialty industrial uses where rigidity and durability matter
Not every supplier offers every gauge as a standard item, so it is normal to see “core thickness families” that align with their production and quality-control capabilities.
What Each Thickness Range Is Best At
Thin Gauges For High Yield And Flexibility
Thin metalized pet, such as 8–12 μm, is often chosen when you need high length per roll and easy conformability. It can run efficiently in high-speed converting, but it may be more sensitive to tension control and web handling.
Key advantages:
Lower material usage per square meter
Good flexibility for tight winding and small-radius forming
Efficient roll logistics
Key considerations:
Higher risk of wrinkles if tension is not stable
Lower stiffness for flatness-critical processes
Mid Gauges For Balanced Performance
The 12–25 μm range is widely used because it balances runnability and performance. It tends to be more forgiving during lamination and slitting, while still maintaining good yield.
Key advantages:
Stable handling and fewer breaks than ultra-thin films
Good balance of stiffness and flexibility
Compatible with many adhesive lamination systems
Key considerations:
Gauge selection should match your converting line tension limits and target roll diameter
Thick Gauges For Stability And Durability
Above 25 μm, the film becomes noticeably stiffer, which can improve flatness and reduce handling defects. It is often selected for industrial laminates or applications requiring stronger mechanical properties.
Key advantages:
Better dimensional stability
Improved puncture and tear resistance versus thin gauges
Easier manual handling for some workshop processes
Key considerations:
Higher material cost per square meter
Lower yield per roll compared to thin gauges
Quick Reference Table Of Common Thickness Choices
| Thickness (μm) | Typical Positioning | Main Strengths | What To Watch |
|---|---|---|---|
| 8–10 | Ultra-light structures | High yield, flexible | Wrinkle sensitivity, tension control |
| 12 | Light-duty laminations | Balanced yield and handling | Confirm flatness requirements |
| 15–16 | General-purpose | Stable converting, good stiffness | Match adhesive and curing profile |
| 19–20 | Premium converting | Better stability and runnability | Slightly higher cost |
| 23–25 | Heavy-duty laminations | Stronger web, improved flatness | Check roll weight and diameter |
| 36–50 | Industrial laminates | High rigidity, durability | Lower yield, higher logistics weight |
This table is a practical starting point for spec discussions, especially when you are comparing multiple laminate structures.
How To Choose The Right Thickness For Your Structure
A reliable selection process is to work backwards from your converting and performance needs:
Converting line capability: thinner films need tighter tension control; thicker films need sufficient unwind and nip force.
Target stiffness and “hand feel”: thicker films look flatter and feel more rigid, which can matter for premium packaging or industrial facings.
Lamination design: if metalized PET is a barrier or decorative layer, mid gauges are common; if it is also contributing to mechanical strength, thicker gauges may be justified.
Roll format and shipping: thicker film increases roll weight quickly, which can affect handling, freight cost, and storage.
If you are building a structure with multiple layers, you usually optimize total laminate performance rather than pushing metalized PET thickness higher than needed.
Specification Details That Should Be Confirmed With Thickness
Thickness alone is not the full spec. For consistent results, confirm these alongside gauge:
Thickness tolerance and how it is measured
Surface treatment level for lamination or printing
Winding hardness, splice policy, and defect standards
Required optical appearance, such as gloss and uniformity
For project buyers and bulk order planning, locking these parameters early reduces re-qualification time during scale-up.
Conclusion
Common thickness options for metalized PET film typically fall into a few practical ranges: 8–12 μm for high-yield flexible webs, 12–25 μm for mainstream lamination and printing structures, and 25 μm and above for higher stability and industrial durability. The best choice depends on your converting conditions, stiffness targets, and how the film contributes to the overall laminate performance.
To review available specifications and application positioning, explore BIYT metalized PET film. If you tell us your target structure, converting method, and roll format, BIYT can help recommend a suitable thickness range and provide practical guidance for stable production runs.