How Should Film Thickness for Lamination Be Chosen?
Thickness is the direct lever between cost and performance: too thin brings pinholes and bonding failures, too thick raises cost and wrinkles in deep corners. Back-calculate the minimum from the barrier target.
Thickness Essentials
Back-calculate from barrier
Derive minimum functional thickness from the target WVTR/OTR.
Pinhole floor
Below 25–30 µm, pinhole risk rises sharply.
Add margin for deep draw
Areas with high stretching need compensating thickness.
Uniformity matters equally
±10% thickness tolerance is the production standard.
Thickness Selection Reference
Starting values; adjust from barrier and forming tests.
| Standard trays | 30–50 µm (EVOH 80–100 µm) |
|---|---|
| Deep-draw trays | 50–100 µm (EVOH 100–150 µm) |
| Barrier laminates | Functional layer: EVOH 5–15% share |
| Pinhole-risk floor | 25–30 µm |
| Thickness tolerance | Within ±10% |
| Measurement | ASTM D6988 / inline gauging |
Thickness FAQ
Is thicker always more moisture-proof?
Broadly yes, but cost rises linearly — use the WVTR target as the guide, not maximization.
Can we start thin and fix it later?
Pinhole leaks can't be patched online — the starting thickness must carry margin.
How to keep thickness uniform?
Choose film supply and equipment with inline gauging and closed-loop thickness control.
Need an Assessment for Your Application?
Share your tray geometry, application and performance requirements — a DNW engineer will help evaluate film structure and process parameters.
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