Kapton® HN Polyimide Film Metallized with Aluminum (30 nm)

Kapton® HN Metallized with Aluminum is DuPont™ Kapton® HN — the ASTM D-5213 reference-grade polyimide — with a precision vacuum-deposited 30 nm aluminum layer on one face. The polyimide substrate provides the thermal range, dielectric strength, dimensional stability, radiation resistance, and low outgassing that make Kapton® HN the material of choice in aerospace and electronics applications. The aluminum layer adds infrared reflectivity for thermal management, controlled EMI attenuation for electromagnetic shielding, and protection against atomic oxygen erosion in low Earth orbit — without significantly adding mass, which is critical in spacecraft applications.

In low Earth orbit, atomic oxygen — produced by photodissociation of molecular oxygen at altitudes between roughly 200 and 700 km — reacts aggressively with bare polymer surfaces, progressively eroding them at rates that would eventually compromise the structural and thermal performance of unprotected polyimide films. The 30 nm aluminum layer acts as a physical barrier between the reactive oxygen species and the polyimide substrate, protecting it from this erosion mechanism and extending the service life of thermal and shielding components on LEO spacecraft. Even a very thin aluminum coating is sufficient to provide this protection, which is why the 30 nm thickness is standard for Multi-Layer Insulation applications.

Aluminum is one of the highest-reflectivity metals across the infrared spectrum, which is why aluminum-metallized Kapton® HN has been the foundational material for spacecraft Multi-Layer Insulation blankets since the early space programme. The 30 nm layer provides strong infrared reflectivity for passive thermal management, as well as controlled EMI attenuation that makes the metallized film suitable for EMI shielding strips around spacecraft harnesses and conductive interfaces in flex circuit assemblies. The layer is thin enough to remain flexible and processable, while thick enough to deliver consistent reflectivity and conductivity across the substrate.

Yes. The substrate is DuPont™ Kapton® HN, the ASTM D-5213 reference-grade polyimide, traceable to DuPont specification. This traceability is a material qualification requirement in aerospace programmes, where the substrate must be documented to a published standard rather than a generic polyimide film. ASTM D-5213 compliance also provides the specification-controlled baseline needed for reproducible experimental results in thermal emissivity, reflectance, metallization adhesion, and LEO performance research.

The Kapton® HN substrate maintains continuous service from cryogenic temperatures to high-temperature extremes — the same thermal range as the uncoated HN grade — with dimensional stability, electrical insulation performance, and aluminum layer adhesion maintained throughout. This makes it suitable for the full thermal environment of spacecraft from launch through on-orbit operation, as well as for electronics assemblies that cycle between processing and operating temperatures.

No. At 30 nm the aluminum coating is thin enough that the composite retains the flexibility and processability of bare Kapton® HN film. It can be die-cut, laser-cut, laminated, and handled in automated processing equipment without cracking or delaminating the metallization under normal processing conditions. This is one reason the 30 nm thickness is the standard specification for spacecraft MLI applications: it provides the required optical and barrier performance while leaving the film fully processable at production scale.

The primary applications are spacecraft Multi-Layer Insulation blankets, where aluminum-metallized Kapton® HN is the established standard reflective layer; reflective thermal barriers for satellite structures; EMI shielding strips for spacecraft harness protection; conductive polymer laminates in sensor assemblies; and thermal emissivity and reflectance characterisation research where a traceable DuPont substrate baseline is a qualification requirement.

Yes. Kapton® HN has low outgassing characteristics that comply with NASA and ESA outgassing requirements for spacecraft materials, and the vacuum-deposited aluminum layer does not add outgassing species. This makes aluminum-metallized Kapton® HN suitable for satellite electronics enclosures, vacuum instrument chambers, and cryogenic assemblies where outgassing from film materials would contaminate optical surfaces, degrade vacuum quality, or interfere with sensitive measurements.

Aluminum-metallized Kapton® HN can be laser-cut, die-cut, and precision-blanked to the required geometry. Laser cutting is preferred for clean, burr-free edges with minimal heat-affected zone, and is well suited to cutting around the aluminum metallization without lifting or cracking the coating. The film can be laminated and incorporated into multilayer thermal stacks. For coil format, roll-to-roll processing including slitting to narrower widths is also applicable.

Choose metallized Kapton® HN when the application requires infrared reflectivity, EMI attenuation, surface conductivity, or atomic oxygen protection in addition to the standard Kapton® HN property profile. Uncoated Kapton® HN is appropriate when the application needs only electrical insulation, thermal stability, dimensional stability, or radiation hardness, and the aluminum layer provides no functional benefit. Uncoated HN also covers a wider thickness range and is lower cost for applications where metallization is not needed.

The flat film format is suited to applications where a defined sheet size is the correct input — precision cutting to non-standard shapes, lamination of individual pieces into thermal stacks, direct-fit installation in spacecraft panels, and sample preparation for thermal emissivity measurements, reflectance characterisation, and metallization adhesion studies where a flat, dimensionally defined piece is the experimental requirement. Flat film pieces are also the right format for prototyping and qualification testing before committing to coil-based production processes.

Kapton® HN Film Metallized with Aluminum is available in thicknesses from 0.025 mm to 0.125 mm in sizes from 10 mm × 10 mm up to 500 mm × 500 mm. Custom cut shapes, laser-profiled outlines, and non-standard sizes are available on request. Contact us with your thickness, dimensions, and required quantity.