Die-Cut Thermal Management Materials

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Components using thermal interface materials, such as die-cut thermal gap pads, provide a path for heat transfer between a heat-generating device and a heat sink or cooling plate.

As our world becomes more connected, we are using more electronic devices that use and store energy. Where there is electric current, there is heat, and heat generated must be transferred away to keep the device running within safe operational temperatures. Too much heat can cause poor device efficiency and even device failure, making thermal management a key requirement for many components.

Thermal Gap Pads, Gap Fillers, Thermal Bonding Tapes, Foil Heat Spreaders, Thermally Conductive Foams

Thermal interface materials are lightweight and easy to handle. Die-cut thermal gap pads and gap fillers, conductive tapes, and foils are often utilized over greases and liquid adhesives due to easy application and consistent performance. Marian can help design and manufacture thermal management components to meet the specifications of your application.

Choosing the Best Thermal Management Materials

Partnering with an expert in thermal interface materials and an industry-leading converter will drastically improve your selection process. Marian’s material experts collaborate with you to fully understand the details of the thermal interface and design challenges. Based on our long history of working with these materials, we are able to suggest the most ideal material and configuration for your assembly.

Material Samples, Rapid Prototypes

Your design process likely demands a range of testing prior to approval of the final material. Marian can provide material samples and rapid prototypes using a number of prototyping capabilities, including laser, water jet, and blade cutting plotters.

Die-Cut Thermal Interface Materials

Silicone thermal gap pads
Acrylic thermal gap pads
Thermal transfer tapes and PSAs
Phase change materials
Heat spreaders / foils – aluminum, copper, graphite
Silicone compounds
Foams and elastomers
Insulator pads
Insulating flexible fiber and paper materials

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FAQs About Thermal Management Materials

Why choose die cut thermal materials over adhesives?

In some cases, thermal management materials like thermal greases and dispensed materials can be very messy and hard to handle. Implementing custom components with die-cut thermal materials can result in a much cleaner solution that’s easy to assemble.

How fast can custom die cut materials be converted?

A variety of things contribute to how quickly a material can be die cut, but depending on quantity and product availability (ex. using a material that is already on our shelves), we can oftentimes produce prototypes within 24-48 hours.

The amount of time for full production runs of an order highly varies, so contact us and we can put you in touch with an engineer in your area that can give you more information after learning about your application needs and timeline.

What factors affect the cost of die cut materials?

The cost of materials that will be die cut for a custom component is determined by a number of factors including:

The specific material being used
Material availability
Quantity of parts required
Part geometry
Partnership with the material supplier – Marian has preferred pricing and access to many materials
And more

Are die cut thermal materials compatible with compact devices?

Thermal management materials are available in a variety of formats and thicknesses depending on application needs. Die cut thermal management materials can be gap pads, conductive tapes and foils, shields, papers, foams, and more.

How do thermal materials perform in extreme temperatures?

Thermal management materials are designed to pull or spread heat away from the heat producing source.

Some thermal materials that are often die cut include: