Formex
ITW Formex insulation refers to a brand-name line of flame-retardant electrical insulation materials manufactured by ITW Formex® and distributed through ESPE Manufacturing Co., Inc. Engineered for high-performance applications, Formex materials combine strong dielectric strength, flame resistance, and mechanical versatility to protect sensitive electronic components across industrial and consumer environments.
Available in both sheets and rolls, Formex material provides a cost-effective alternative to traditional insulation solutions without compromising reliability, safety compliance, or long-term performance. Its balance of electrical protection and fabrication flexibility makes it a preferred choice in modern electronic design.
As a top ITW Formex distributor, we offer the full range of ITW Formex products including:
Applications of Formex | ESPE Manufacturing
Uses of Formex Insulating Material
Formex material is composed of flame-retardant polypropylene that prevents electrically charged components from arcing, protecting the users, equipment, and maintenance personnel. In the event of electrical fire, these flame retardant properties assure that the Formex material will not melt or combust up to 115°C / 239°F. It appears in a variety of applications as an electrical insulator and barrier.
Find Formex materials in the following applications:
- Cloud data centers
- Industrial controls
- LED lighting
- Electrical power distribution
- Consumer electronics
Applications Electrical and electronic insulation
- EV battery packs
- EV onboard chargers
- EV DC/DC converters
- EV power electronics controllers
- EV DC charging stations
- PV solar power inverters
- LED drivers
- EV battery management systems
- Panelboard barriers and insulators
- Industrial power terminal insulation
- Power supplies
- AI speakers
- Home appliances
- Personal computers
- Patient treatment
- Monitoring
- Testing
- Automated drug dispensing
- Pulse detection
- Blood pressure sensing
- Electrocardiogram instrumentation
- Formex barriers exist between PC boards and housings to prevent access to dangerous areas within the equipment.
Types of Formex® Materials at ESPE Manufacturing
As an authorized ITW Formex distributor, ESPE Manufacturing offers fabrication and distribution of Formex GS, GK, GL, and N3 in both sheet and roll formats. Each grade of Formex material is engineered to meet specific application requirements, allowing engineers to match thermal, dielectric, and environmental needs with precision.
Formex® GK
Formex GK
Formex® GK is a widely used flame-retardant polypropylene solution and one of the most versatile electrical insulation materials in the Formex line. It is designed for long-term durability in demanding environments and offers excellent dielectric strength and chemical resistance.
Its ability to be scored, folded, and formed into complex shapes reduces manufacturing complexity, shipping costs, and storage requirements.
Product Features:
- Available in thicknesses from 0.005″ through 0.125″ inch
- Available in thicknesses from 0.13 mm through 3.18 mm
- 115°C / 239°F continuous-use temperature rating
- UL 94V-0 for 0.017″ and above
- UL 94VTM-0 for 0.005″ and 0.010″
- Superior dielectric strength
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Formex GK
Formex® GK is a widely used flame-retardant polypropylene solution and one of the most versatile electrical insulation materials in the Formex line. It is designed for long-term durability in demanding environments and offers excellent dielectric strength and chemical resistance.
Its ability to be scored, folded, and formed into complex shapes reduces manufacturing complexity, shipping costs, and storage requirements.
Product Features:
- Available in thicknesses from 0.005″ through 0.125″ inch
- Available in thicknesses from 0.13 mm through 3.18 mm
- 115°C / 239°F continuous-use temperature rating
- UL 94V-0 for 0.017″ and above
- UL 94VTM-0 for 0.005″ and 0.010″
- Superior dielectric strength
Formex® GS (formerly Statex)
Formex GS (formerly Statex)
Formex® GS is a static-dissipative Formex material designed to protect electronic systems from electrostatic discharge (ESD). It functions as both an insulator and a controlled pathway for safely dispersing static energy away from sensitive components.
Product Features:
- Available in 0.010″, 0.017″, and 0.030″ inch thickness
- Available in 0.25 mm, 0.43 mm, and 0.76 mm thickness
- 110°C / 230°F continuous-use temperature rating
- UL 94V-0 for 0.012″ and 0.030″ thicknesses
- UL 94VM-0 for 0.010″ thickness
- Static-dissipative ESD protection
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Formex GS (formerly Statex)
Formex® GS is a static-dissipative Formex material designed to protect electronic systems from electrostatic discharge (ESD). It functions as both an insulator and a controlled pathway for safely dispersing static energy away from sensitive components.
Product Features:
- Available in 0.010″, 0.017″, and 0.030″ inch thickness
- Available in 0.25 mm, 0.43 mm, and 0.76 mm thickness
- 110°C / 230°F continuous-use temperature rating
- UL 94V-0 for 0.012″ and 0.030″ thicknesses
- UL 94VM-0 for 0.010″ thickness
- Static-dissipative ESD protection
Formex® GL
Formex GL
Formex® GL is an advanced thin-profile version of Formex GK, offering improved temperature resistance while maintaining mechanical strength and electrical performance.
It is ideal for compact systems where space is limited but reliability cannot be compromised.
Product Features:
- Available in 0.010″ and 0.011″ inch thickness
- Available in 0.25 mm and 0.43 mm thickness
- 125°C / 257°F continuous-use temperature rating
- UL 94VTM-0 Flame Class Rating for 0.25 mm
- UL 94V-0 Flame Class Rating for 0.43 mm
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Formex GL
Formex® GL is an advanced thin-profile version of Formex GK, offering improved temperature resistance while maintaining mechanical strength and electrical performance.
It is ideal for compact systems where space is limited but reliability cannot be compromised.
Product Features:
- Available in 0.010″ and 0.011″ inch thickness
- Available in 0.25 mm and 0.43 mm thickness
- 125°C / 257°F continuous-use temperature rating
- UL 94VTM-0 Flame Class Rating for 0.25 mm
- UL 94V-0 Flame Class Rating for 0.43 mm
Formex® N3
Formex N3
Formex® N3 is a halogen-free, flame-retardant polycarbonate-based formex material designed for high-performance electronics and environmentally sensitive applications.
Its thin profile and strong electrical insulation capabilities make it suitable for compact and regulated designs.
Product Features:
- Available in 0.008″ and 0.010″ inch thickness
- Available in 0.20 mm and 0.25 mm thickness
- 130°C / 266°F continuous-use temperature rating
- UL 94VTM-0 Flame Class Rating
- Halogen-free polycarbonate
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Formex N3
Formex® N3 is a halogen-free, flame-retardant polycarbonate-based formex material designed for high-performance electronics and environmentally sensitive applications.
Its thin profile and strong electrical insulation capabilities make it suitable for compact and regulated designs.
Product Features:
- Available in 0.008″ and 0.010″ inch thickness
- Available in 0.20 mm and 0.25 mm thickness
- 130°C / 266°F continuous-use temperature rating
- UL 94VTM-0 Flame Class Rating
- Halogen-free polycarbonate
Formex® Applications
ITW Formex insulation is widely used as both a protective barrier and an electrical insulation layer in systems where space efficiency, flame resistance, and dielectric strength are critical. Their ability to be scored and folded into three-dimensional shapes makes them especially attractive for compact product designs.
Electrical & Electronic Insulation
Formex materials are extensively used in power, energy, and high-voltage systems where reliable insulation is non-negotiable. Common applications include:
- EV battery packs
- EV onboard chargers
- EV DC/DC converters
- EV power electronics controllers
- EV battery management systems
- EV DC charging stations
Formex® is also widely used in renewable energy and industrial power applications such as:
- PV solar power inverters
- LED drivers
- Panelboard barriers and insulators
- Industrial power terminal insulation
Across these applications, engineers choose Formex® for its consistent electrical protection, compact design compatibility, and long-term reliability — even in environments with thermal, chemical, or moisture challenges.
Consumer Electronics & Smart Home Devices
Formex® insulating materials are trusted components in a wide range of consumer electronics and smart home devices where compact form factors and component protection are essential. Typical applications include:
- Power supplies
- Personal computers
- AI-enabled speakers
- Home appliances
In these products, Formex® helps prevent electrical interference while supporting the efficient, compact product designs demanded by today’s market.
Medical & Healthcare
Formex® materials meet the stringent reliability standards required in medical and healthcare environments. Applications include:
- Patient treatment equipment
- Monitoring and testing devices
- Automated drug dispensing systems
- Pulse detection devices
- Blood pressure sensing equipment
- Electrocardiogram (ECG) instrumentation
In these settings, Formex® prevents electrical interference and supports the precise, dependable performance required in life-critical instruments.
Electrical Safety Barriers
Formex® barriers are routinely installed between printed circuit boards (PCBs) and equipment housings to prevent access to hazardous or energized areas. Common barrier applications include:
- PCB-to-housing isolation in consumer and industrial electronics
- Protection of user-accessible surfaces near energized components
- Barriers within user-serviceable enclosures
- Compliance support for applicable electrical safety standards
These barriers help improve safety, reduce risk, and ensure sensitive circuitry remains protected wherever it is in proximity to accessible surfaces or service points.
Features
Formex material offers a range of desirable features for users, including:
- UL 94V-0 Flame Class Rating meets global standards for safety
- Non-hygroscopic (ultra-low <0.06% moisture absorption)
- Excellent dielectric strength shields against electrical surges
- Chemical resistance maintains mechanical and electrical properties
- Superior scoring, folding, and bending capabilities—parts do not split or crack
- Competitive pricing
Formex processing occurs using a variety of methods, including:
- Die cutting for engraved, rotary, steel rule, and male/female dies
- Laser/water jet cutting for rapid prototyping and high-speed production
- Heat forming to produce permanently formed angles on parts with low-cost tooling
- Machining using conventional techniques for easy fabrication
- Thermoforming to produce rigid, three-dimensional complex shapes
Additional processing available for Formex insulating materials includes:
- Lamination with copper or aluminum foil for EMI and RFI shielding
- Addition of adhesives for various applications
- Marking to add embossed or printed product ID or part numbers as well as safety or technical information
- Welding to bond Formex to itself with conventional techniques
- Joinery methods to create parts and eliminate external fastening
Insulation for all occasions
Formex materials have a wide variety of uses in a number of electrical insulation applications, from manufacturing to consumer products. This flame-retardant material prevents electric surges by shielding electrical parts, preventing arcing, burning or fire.
ESPE Manufacturing offers a great selection of electrical insulation materials like Formex for your applications. We’re a top ITW Formex distributor, serving numerous industries. We will be happy to help you select the right electrical insulators and barriers for your application’s needs. Browse our catalog to find a full list of ITW Formex materials and applications, or contact us for more info!
Technical Data Sheet
Fabrication and Customization Capabilities
As a trusted ITW Formex distributor, ESPE Manufacturing Co., Inc. provides full fabrication support for Formex material, delivering finished parts tailored for electrical and electronic applications.
ESPE offers cutting and converting services such as die cutting, laser cutting, and precision machining to produce accurate and repeatable components for complex designs.
We also provide forming and assembly capabilities, including heat forming, thermoforming, folding, scoring, and bonding, allowing flat electrical insulation materials to be shaped into functional three-dimensional parts.
In addition, ESPE delivers value-added services like adhesive backing for easy installation, EMI/RFI shielding laminations for enhanced protection, and printing or labeling for identification and assembly guidance.
Through these capabilities, ESPE transforms Formex material into application-ready insulation solutions that meet the performance and design demands of modern electrical systems.
Your Trusted ITW Formex® Distributor
Formex® materials serve a broad spectrum of electrical insulation applications — from manufacturing environments to finished consumer products. This flame-retardant material shields electrical parts from arcing, burning, and fire, providing dependable protection across the product lifecycle.
As an authorized ITW Formex® Master Distributor and Fabricator, ESPE Manufacturing offers a carefully curated selection of Formex® insulation materials for your specific application. We serve numerous industries and bring deep application knowledge to every engagement, helping you select the right material, in the right form, at the right thickness.
Browse our catalog for a full listing of available ITW Formex® materials and configurations, or contact our team directly for application-specific guidance and a quote.