Solving Aerospace Insulation Challenges with Formex™ GK

The aerospace industry is no stranger to harsh environments. From high-altitude commercial aviation to low-orbital satellites, modern aerospace applications must brave extreme temperatures, speeds, and pressures day in and day out. These demanding environments serve as proving grounds for performance materials, where even the slightest defect can spell disaster.

Aerospace manufacturers need high-performance materials that don’t buckle under challenging conditions. As the boundaries of aerospace continue to be pushed, material innovation will need to keep up.

Today's material spotlight focuses on Formex™ GK, a material that solves many challenges aerospace engineers face, from electrical insulation to EMI/RFI Shielding. 

What is Formex™ GK?

Formex™ GK is a high-performance polypropylene-based insulation material that was engineered for use anywhere sensitive electronic components are tightly packed together, such as wiring harnesses and battery packs. GK material acts as an insulator or barrier to keep sensitive electronics from touching and mitigate the potential for dangerous short circuits, communication/navigation failures, and even fires.

Key Characteristics of Formex ™ GK:

·         High dielectric strength

·         UL -94 V-0 flame retardancy

·         Moisture and chemical resistance

·         Customizable

·         Affordable

·         Lightweight

A High-Performance Alternative

Compared to common alternative insulation materials like fish paper, Nomex, and other polycarbonates, Formex™ GK stands out as a versatile aerospace insulation tool. 

Dielectric Strength

Formex™ GK provides excellent dielectric strength, ranging from 2,200 volts/mil (0.005”) to 670 volts/mil (0.0625”). Dielectric strength scales with thickness.

Alternatively, fish paper has a dielectric strength of 215 volts/mil at 0.0625” thick, while Nomex has a strength of 850 volts/mil at 0.0625”.

Flame Retardancy

Formex™ GK boasts a UL-94 V-0 fire retardancy rating with self-extinguishing capabilities, preventing fires from getting out of control.  

Moisture and Chemical Resistance

Materials like fish paper absorb moisture, which decreases their dielectric strength while increasing weight. On the other hand, Formex™ GK has a low absorption rate of 0.06, making it resistant to harmful moisture.

Pro tip: GK material is also UL F1 rated, making it resistant to UV rays and harsh outdoor environments!

Convertibility (Customization)

Easily folded, scored, or die-cut, the Formex™ GK solution is flexible enough to adapt to the tight spaces and complex geometries of aerospace electronics compartments. Formex™ GK can be sourced in both rolls and sheets, allowing the converter to optimize production throughput and post-processing needs.

Important Consideration: Want to add a peel-and-stick backing to your Formex™ part? Or laminate it to a different substrate for multi-functional benefits? It's important to work with a converter to select an adhesive that is compatible with flame-retardant polypropylene. 

Aerospace Applications:

EMI/RFI Shielding

Electromagnetic interference can interrupt critical communication and navigation systems. When laminated with copper foil, Formex™ GK blocks harmful EMI/RFI while acting as an effective electrical barrier.

Pro tip: Working with a converting partner to laminate two high-performance materials together is the key to getting the most out of your insulation materials. (Like Formex™ GK!)

High Operating Temperature Insulation

Aerospace components must be able to safely handle the heat of typical operating temperatures. With an RTI of 115C, GK material can withstand temperatures from -40°C to 115°C, making it a reliable choice for demanding high operating temperature applications. 

Electrical Insulation

Formex™ GK protects sensitive electronic components from dangerous surges or arcing anywhere high voltages and tight spaces are present, without any bulk or excess weight.

Lightweighting

With a low density of 1.035 g/cc, GK material helps eliminate weight without sacrificing performance.

About JBC Technologies

At JBC, we understand that selecting the right insulation material for your aerospace project is no easy task. JBC Technologies provides material selection assistance and rapid prototyping services through our digital dieless cutting capabilities to validate your parts design and material choices. Whether it’s custom die-cut EMI/RFI shielding, gaskets, seals, or thermal and electrical insulation, JBC helps engineer scalable aerospace solutions that support your automation and supply chain needs.  

Contact JBC Technologies today to get started on your next custom die-cutting project.