Orion Industries is a proud converter of a large range of well-known and trusted electrical insulation materials such as Formex, Lexan and Mylar. Orion has the material options to suit your needs this season.
The versatility of our insulation materials, Lexan, Formex and Mylar, each offer distinct insulation advantages that make them valuable in electrical and electronic applications. Mylar, a polyester film, provides excellent dielectric strength, thermal stability, and moisture resistance, making it ideal for insulating cables, transformers, and capacitors. Lexan, a polycarbonate material, combines high impact resistance with good electrical insulation properties, maintaining performance even under mechanical stress or elevated temperatures. Formex, a flame-retardant polypropylene, delivers outstanding dielectric strength and ease of fabrication, often used for electrical barriers, insulation panels, and circuit board shields. Together, these materials offer reliable electrical insulation, durability, and safety across a wide range of environments
Formex
Formex is a flame-retardant polypropylene material known for its excellent electrical insulation and stable thermal performance. It acts as a thermal barrier rather than a conductor, maintaining dimensional stability and strength at temperatures up to 120 °C. Since it absorbs very little moisture and resists heat deformation, Formex is ideal for electrical insulation, battery spacers, and barriers in electronics, where it helps protect components from heat and electrical discharge while remaining lightweight and easy to form.
Lexan FR Series
Lexan, a durable polycarbonate material, offers excellent electrical insulation along with high mechanical strength and heat resistance. It maintains its insulating properties even under stress, vibration, or elevated temperatures. Their FR series It is flame-retardant, UL94 V-0 rated. Its combination of transparency, toughness, and dielectric strength allows Lexan to provide both safety and performance in demanding electrical and electronic applications.
Mylar
Mylar is a polyethylene film that exhibits strong thermal-barrier characteristics. Typical applications include insulation wrap in electrical motors, capacitors, and battery systems, reflective shields for radiation heat, protective layering in thermal-barrier assemblies, and packaging films where thermal stability and moisture resistance are needed.
When considering your options for electrical insulation materials, consider these factors:
Thermal Properties
Formex: Moderate heat resistance, acts as a thermal barrier. Lexan FR: Higher heat deflection but better for structural transparency. Mylar: Highest thermal endurance and excellent thermal stability and resistance to shrinkage.
Electrical Insulation
Formex: Outstanding dielectric strength which is ideal for insulating electrical and electronic components. Lexan FR: Mainly chosen for mechanical and optical qualities. Mylar: Excellent electrical insulation
Strength & Durability
Formex: Strong and flexible; foldable and formable without cracking. Lexan FR: Exceptional impact resistance; surface is scratch and UV-resistant due to its hard coating. Mylar: Tough but thin; resists tearing and puncturing but not as rigid as polycarbonate.
Environmental & Chemical Resistance
Formex: Good resistance to moisture and many chemicals; UL94 V-0 flame rating. Lexan FR: Excellent weather and UV resistance Mylar: Very low moisture absorption, resistant to oils and many solvents, stable in humid or harsh environments.
For more information, please look at our material specification sheets or reach out to your Orion sales rep for more information!