What Is Metallised PET Film?

Metallised pet film is a high-performance polyester film coated with a thin layer of metal — usually aluminum — through a vacuum metallization process. This coating gives the film a shiny metallic appearance, along with enhanced barrier, reflective, and insulation properties. It’s widely used in packaging, insulation, printing, electronics, and window film applications due to its combination of durability and visual appeal.

1. What Metallised pet film Is Made Of

The base of metallised PET film is Polyethylene Terephthalate (PET) — a strong, transparent polymer known for its tensile strength, flexibility, and thermal stability. During production, a thin metallic layer (typically aluminum) is applied to one side through vacuum deposition.

Composition:

• PET substrate: Provides mechanical stability and transparency.

• Metal coating: Reflects light and blocks moisture, oxygen, and UV rays.

• Optional coatings or primers: Improve adhesion, printability, or heat seal performance depending on end use.

The result is a lightweight material that combines the clarity of plastic with the resilience and reflectivity of metal.

2. Key Properties and Performance Advantages

Metallised PET film is engineered for optical, chemical, and mechanical stability. Its surface and core properties make it suitable for both industrial and decorative applications.

a) High Reflectivity

The metallic layer reflects up to 98% of visible and infrared light, making it ideal for thermal insulation, solar control, and visual enhancement in reflective products.

b) Excellent Barrier Protection

It offers low permeability to gases and moisture, extending the shelf life of food and sensitive materials. This makes it essential in snack packaging, coffee pouches, and pharmaceutical wraps.

c) Strength and Tear Resistance

PET’s natural tensile strength ensures durability during lamination, printing, or forming. It resists tearing and puncturing better than standard plastic films.

d) Heat and Chemical Resistance

Metallised PET can withstand temperatures between –70°C and +150°C, maintaining stability in extreme conditions. It’s also resistant to oils, acids, and most solvents.

e) Lightweight and Recyclable

Despite its metallic look, metallised PET film remains thin, flexible, and recyclable, reducing transportation costs and environmental impact.

3. How Metallised PET Film Is Made

The production process involves several controlled stages to ensure consistent performance and optical clarity.

Step 1: PET Film Extrusion

Molten PET resin is extruded into a thin film and cooled on polished rollers to create a uniform base layer.

Step 2: Metallization

In a vacuum chamber, aluminum is vaporized and deposited evenly onto the PET surface. This forms a microscopic metal layer (typically 20–50 nanometers thick) that bonds with the film without altering its flexibility.

Step 3: Coating and Finishing

Additional surface treatments or coatings may be added for heat sealing, print adhesion, or anti-static performance. The finished film is wound into rolls for cutting, lamination, or further processing.

This controlled metallization process ensures a smooth, reflective, and durable finish that maintains optical and mechanical integrity.

4. Industrial and Commercial Applications

Metallised PET film’s versatility makes it valuable across multiple industries, each using its reflective and barrier properties in unique ways.

a) Food and Beverage Packaging

Used in chips, coffee, and dairy pouches, it prevents oxygen and moisture from spoiling contents while maintaining a premium metallic appearance.

b) Insulation and Building Materials

As a thermal barrier, metallised PET is used in reflective insulation, HVAC ducts, and radiant barriers to reduce heat transfer and improve energy efficiency.

c) Printing and Decorative Design

Its glossy finish supports high-quality printing, lamination, and holographic effects, ideal for labels, gift wraps, and luxury product packaging.

d) Electrical and Electronic Uses

Because of its dimensional stability and dielectric strength, metallised PET is used for capacitor insulation, cable wrapping, and circuit shielding.

e) Window and Solar Films

When applied to glass, the metallic layer reflects sunlight and blocks UV rays, improving comfort and energy savings in buildings and vehicles.

5. Comparison with Other Films

Metallised PET offers the best balance of appearance, performance, and flexibility, bridging the gap between plastic films and metal foils.

6. Storage and Handling Recommendations

• Keep rolls in a cool, dry environment away from direct sunlight.

• Avoid contact with sharp tools or hard surfaces to prevent scratching.

• Maintain stable humidity (40–60%) to prevent static buildup.

• Use anti-dust packaging when transporting or storing large rolls.

Following these guidelines preserves the film’s reflective finish and prevents premature oxidation or delamination.

Conclusion

Metallised PET film is a high-strength, reflective polyester material that combines the protective qualities of metal with the flexibility of plastic. Through advanced vacuum metallization, it delivers exceptional light reflection, gas barrier protection, and temperature resistance.

From packaging and insulation to decorative and electronic applications, metallised PET film remains one of the most versatile and cost-effective materials for industries that demand both performance and aesthetics.