Gap pads – die-cut thermal interface materials
Have you ever been faced with an overheated component in a prototype or product where the heat sink isn't quite doing the job? Finding the right thermal interface material - that really fits your application - is not always easy. With our stamped gap pads we help you solve thermal challenges with precision, control and reliable performance.
What is a gap pad and why is it important?
In gap pad, also known as gap filler, is a thermally conductive material in the form of a soft, flexible pad. It is placed between heat-generating components, such as processors or power modules, and heat sinks or chassis. The aim is to fill microscopic irregularities and improve heat transfer, thereby reducing the risk of overheating and extending the service life of the electronics.Materials and performance: which gap pad material is right for you?
We work with a wide range of thermally conductive materials, from standard silicone-based products to advanced gap fillers with reinforcement for vibration-sensitive environments. Here are some typical properties you should consider:- Thermal conductivity: measures how effectively the material conducts heat away; it is expressed in W/mK.
- Thickness: We die-cut gap pads from as thin as 0.3 mm up to several millimetres, perfect for various construction heights.
- Compatibility: Our materials are often UL-approved, halogen-free and suitable for both mobile and stationary devices.
- Surface texture and adhesion: We offer self-adhesive options and textured surfaces for better grip.
Gap pad types: technical reference values
| Property | Standard type, silicone | Soft/ultra-soft, silicone | Silicone-free |
|---|---|---|---|
| Thermal conductivity | 1.0–3.0 W/mK | 1.5–6.0 W/mK | 1.0–5.0 W/mK |
| Thicknesses | 0.5–5.0 mm | 0.3–5.0 mm | 0.5–3.0 mm |
| Hardness, Shore 00 | 40-70 | 10-40 | 30-70 |
| Density | 2.5–3.5 g/cm³ | 2.0–3.0 g/cm³ | 1.5–2.5 g/cm³ |
| Temperature range | -60 to +200 °C | -60 to +200 °C | -60 to +150 °C |
| Dielectric strength | > 8 kV/mm | > 6 kV/mm | > 5 kV/mm |
| UL fire rating | UL94 V-0 | UL94 V-0 | Varies |
| Halogen-free | Varies | Varies | Yes, usually |
Silicone-based vs silicone-free gap pads
The choice between silicone and silicone-free depends on the requirements of the application: Silicone-based gap pads: These are the most common and come in the widest range of variants. They offer good thermal conductivity, a wide temperature range and a long service life. Soft variants, such as ultra-soft, are well suited where the gap varies or the components are sensitive to mechanical stress. The disadvantage is that silicone-based materials can emit small amounts of siloxanes, which can be a problem in environments containing optical components or certain sensors. Silicone-free gap pads: Used in applications where siloxane outgassing is not tolerated, such as in optical systems, hard disk drives, relay and contact technology, and certain medical device applications. They are available in an increasing number of variants with competitive W/mK values, but the range is still somewhat limited. Not sure? We can help you decide. Contact us along with your application description.Thicknesses and shapes we die-cut
We die-cut gap pads in sizes ranging from approximately 3 × 3 mm up to large-format sheets, depending on the material. Standard thicknesses we stock: 0.3 mm · 0.5 mm · 1.0 mm · 1.5 mm · 2.0 mm · 2.5 mm · 3.0 mm · 4.0 mm · 5.0 mm Delivery methods:- Punched-out loose parts: ready to be positioned and fitted.
- Kiss-cut on sheets: are picked directly from the carrier sheet.
- Kiss-cut on a roll: for automated assembly in higher volumes.
Die-cutting of gap pads: tailor-made to your design
At Stans-Service, we punch gap pads exactly to specification, whether you need small components – such as 3 × 3 mm – or larger shapes. We handle both prototypes and high-volume production with short lead times and a high degree of repeatability.- Top die-cutting/kiss-cut: self-adhesive pads on sheets or rolls.
- Special format: customised cut-outs, holes and shapes.
- Precise tolerances: tailored to the requirements of your application.
How to choose the right gap pad: 3 questions to ask yourself
- How much heat needs to be dissipated? Take into account the power loss in your component and the distance to the heat sink.
- What surface contact do you have between component and cooling? Uneven surfaces require softer and thicker materials.
- What are the requirements for assembly and strength? Is adhesion, vibration damping or electrical insulation required?
Gap pad or thermal paste: what’s the difference?
A thermal paste fills microscopic areas but is more difficult to apply evenly, especially in automated production. Gap pads are cleaner to handle, easier to assemble and provide better repeatability in both prototype and series.Why choose Stans-Service for your gap pads?
We have a wide range of thermal interface materials in stock at our premises in Bromma, Stockholm, and are in daily contact with suppliers to ensure we can quickly source special variants. Having production and warehousing under one roof offers you:- Short delivery times: We cut to size from stock and deliver within a few working days.
- High level of expertise in materials: We compare W/mK values, compression curves and temperature ranges on a daily basis.
- Flexible production: from individual prototypes to ongoing series production.
- Personal advice: We’ll help you compare materials and specifications, and send you samples for testing.
- Local supplier in Sweden: faster decision-making and simpler communication compared with global materials manufacturers.