Insulation material selection directly affects flexibility, temperature performance, durability, and handling characteristics. Temperature rating and durometer should be evaluated together based on operating conditions and mechanical demands.

Common Insulation Materials

PVC (Polyvinyl Chloride)

  • Temperature range: approximately -20°C to +105°C
  • Durometers from very soft to semi-rigid
  • Cost-effective and widely used
  • Available in medical-grade and specialty formulations

TPR (Thermoplastic Rubber)

  • Temperature range: approximately -40°C to +105°C
  • Softer feel than standard PVC
  • Improved low-temperature flexibility
  • Good fatigue resistance in dynamic applications

Polyurethane

  • Temperature range: approximately -40°C to +90°C
  • Excellent abrasion and cut resistance
  • Higher tensile strength than PVC or TPR
  • Maintains flexibility under repeated motion

Fluoropolymers (FEP, ETFE, PFA)

  • Temperature range: approximately -80°C to +200°C (material dependent)
  • Stable electrical properties
  • Excellent chemical and moisture resistance
  • Typically firmer than PVC or TPR

Durometer Considerations

  • Lower durometer: Increased softness and flexibility
  • Higher durometer: Improved abrasion resistance and shape retention
  • Durometer selection impacts handling feel, bend radius, and fatigue life

Very soft compounds are often used for medical, wearable, and handheld applications.

Selecting Insulation

Insulation should be selected based on temperature exposure, motion requirements, chemical environment, and handling needs. Gavitt works with customers to balance temperature rating, durometer, and mechanical performance for each application.