ultra-thin foils
Built for clean features and controlled handling.
Thin materials leave little room for process variation.
Small changes in burr condition, flatness, plating, strip control, or handling can affect fit, electrical performance, and downstream assembly.
Gromax supports precision foil components used in electronics, sensors, batteries, shielding, medical devices, wearables, and compact electromechanical products.
Foil Contacts
Precision stamped conductive contacts used in compact electronic, sensing, connector, and medical device assemblies. Typical thickness range: 0.001"–0.006"
Battery Tabs
Thin conductive stampings used to create electrical connections inside battery-powered products, portable electronics, battery modules, and compact energy-storage assemblies. Typical thickness range: 0.002"–0.012"
Shielding Foils
Precision stamped foil components used for EMI/RF shielding, grounding, electrical continuity, and noise reduction inside electronic assemblies.Typical thickness range: 0.0005"–0.005"
Sensor Foils
Ultra-thin conductive components used in pressure, position, temperature, fluid, diagnostic, wearable, and industrial sensing applications. Typical thickness range: 0.0005"–0.004"
Grounding Foils
Thin conductive stampings used to establish grounding paths, connect shielded areas, reduce electrical noise, and maintain continuity between PCB assemblies, housings, displays, covers, or metal frames. Typical thickness range: 0.001"–0.006"
Leadframe-Style Foils
Thin conductive structures used inside miniature electronic assemblies, sensor packages, insert-molded components, connector modules, and compact electromechanical devices. Typical thickness range: 0.002"–0.010"
Flexible Contact Components
Thin-gauge stamped contacts designed for controlled electrical engagement in tight spaces where package height, contact pressure, and repeatable deflection matter. Typical thickness range: 0.0015"–0.008"
Conductive Foil Elements
Thin stamped conductive features used to carry low-current signals, provide electrical paths, bridge circuit areas, or support compact electrical functions inside small assemblies. Typical thickness range: 0.0005"–0.006"
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common applications
Ultra-thin foil stampings are used where material thickness, electrical performance, flatness, clean edges, surface condition, and careful handling affect product reliability.
Residential EV Charging Station
Foil contacts, grounding foils, conductive tabs, EMI/RF shielding foils, plated contact strips, and thin power-interface features are realistic fit points inside compact EV charging hardware.
Rugged GPS Smartwatch
Foil contacts, sensor foils, grounding foils, shielding foils, charging contacts, battery tabs, flexible contact components, and compact conductive foil elements are realistic fit points inside rugged wearable electronics.
Tactical Handheld Radio
Shielding foils, grounding foils, RF contact features, board-level conductive interfaces, antenna-related contact elements, rugged connector contacts, and thin EMI/RF shield components may be used inside tactical communication systems.
PLC Interface Relay Module
Foil contacts, grounding foils, relay contact features, leadframe-style foils, terminal-interface components, formed conductive elements, and small spring contact features may support signal switching, isolation, terminal engagement, and compact electrical connection in automation panels and machine-control systems.
Insulin Pump System
Sensor foils, conductive foil elements, battery tabs, grounding foils, shielding foils, sensing contacts, connector contacts, and compact insert-molded conductive features may support wearable or body-worn medical electronics.
Waterproof Industrial Connector System
Leadframe-style foils, stamped terminals, conductive foil inserts, grounding elements, shield contacts, crimp features, and formed contact components can be positioned inside molded or overmolded connector bodies to create sealed, ready-to-plug connections for industrial automation, power, signal, hybrid connection, sensor wiring, and rugged field equipment.
when
GROMAX
is a good fit
Material Handling Is Critical
Thin strip can wrinkle, curl, buckle, stretch, or distort during feeding, stamping, plating, handling, and packaging.
The process must protect the material from the start.
Fine Features Must Stay Clean
Narrow webs, small slots, tiny holes, fine tabs, and delicate contact areas require stable tooling and controlled strip support.
Burr Condition Matters
Even a small burr can affect:
• Electrical contact
• Mating fit
• Welding
• Overmolding
• Sealing
• Operator handling
• Assembly wear
• Sensor response
Burr direction and edge condition should be reviewed early.
Flatness And Shape Must Be Controlled
Thin parts can distort easily after stamping, forming, plating, or separation from the carrier.
Flatness, curl, twist, and local deformation may all affect final assembly.
Plating Can Change The Part
Tin, nickel, silver, gold, and other finishes can affect:
• Final thickness
• Contact geometry
• Solderability
• Conductivity
• Surface condition
• Flexibility
• Assembly fit
Plating buildup and handling should be considered before tooling is locked.
Packaging Is Part Of The Process
A stable stamping process can still fail if finished parts tangle, bend, scratch, or stick together during shipping and handling.
Packaging should be designed around the part’s geometry and fragility.
Typical Thickness Guidance
Ultra-thin foil parts may range from very light shielding and sensor foils to thicker battery tabs and leadframe-style components.
Typical ranges may include:
• Fine shielding or sensor foils: approximately 0.0005″ to 0.005″
• Foil contacts and grounding foils: approximately 0.001″ to 0.006″
• Leadframe-style foils: approximately 0.002″ to 0.010″
• Battery tabs: approximately 0.002″ to 0.012″
Actual feasibility depends on:
• Material
• Temper
• Feature size
• Burr requirements
• Forming needs
• Plating stack
• Handling method
• Inspection approach
• Annual volume
Thickness ranges are general guidance, not automatic process limits.
Have an ultra-thin foil part you’d like us to review?
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Export Control
& Confidentiality Notice
To comply with ITAR, DFARS, and applicable U.S. export control regulations, Gromax does not display actual customer parts, drawings, specifications, or technical data in public-facing materials.
Images shown are illustrative only and are used to represent Gromax’s design and manufacturing capabilities. They do not contain proprietary, controlled, or export-restricted information.