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HITHERM™ HT-1205, HT-1210, HT-2505, HT-2510 & HT-C3200 – Custom Die Cutting

by | Dec 20, 2025 | Artificial Intelligence, Die Cutting, Thermal Pads

electronic, space

electronic, space

Flexible Graphite Thermal Interface Materials for Long-Life, High-Reliability Electronics

As electronics push higher power densities and longer service lives, traditional thermal greases and soft gap pads increasingly become reliability risks. Pump-out, dry-out, and re-torque requirements introduce long-term maintenance concerns—especially in LED lighting, telecom, and power electronics.

HITHERM™ flexible graphite thermal interface materials eliminate these failure modes by using a solid, assembly-ready graphite foil that delivers consistent thermal performance from initial installation through end-of-life.

This article covers five commonly specified HITHERM part numbers:

  • HT-1205 / HT-1205A(PSA version)

  • HT-1210 / HT-1210A(PSA version)

  • HT-2505 / HT-2505A(PSA version)

  • HT-2510/ HT-2510A(PSA version)

  • HT-C3200

Understanding the HITHERM Product Structure

HT-1200 Series – Pure Flexible Graphite (Same Material, Different Thicknesses)

HT-1205 and HT-1210 are the same pure flexible graphite material.
The only difference is thickness.

Part Number Nominal Thickness
HT-1205 0.127 mm (0.005”)
HT-1210 0.25 mm (0.010”)

This material is optimized for high-temperature, long-life applications where dimensional stability and thermal consistency matter more than extreme compressibility. Adding an “A” to the end makes the material come with PSA adhesive backing.

Typical applications include:

  • Chip-on-board LED devices

  • Custom LED light engines

  • Electronics exposed to wide thermal cycling

Operating temperature range: –40 °C to +400 °C. 

HT-2500 Series – Polymer-Enhanced Graphite (Same Material, Different Thicknesses)

HT-2505 and HT-2510 are also the same material, differentiated only by thickness.

Part Number Nominal Thickness
HT-2505 0.127 mm (0.005”)
HT-2510 0.25 mm (0.010”)

The HT-2500 material uses polymer enhancement to reduce thermal impedance at lower clamping forces, making it ideal for electronics assemblies where mechanical load is limited. Adding an “A” to the end makes the material come with PSA adhesive backing.

Typical applications include:

  • CPU and GPU thermal interfaces

  • Telecommunications hardware

  • Embedded electronics and control systems

Operating temperature range: –25 °C to +125 °C

HT-C3200 – High-Pressure, High-Performance Graphite (Distinct Material)

HT-C3200 is a different material altogether, designed specifically for:

  • Large surface areas

  • High contact pressure

  • Maximum thermal performance

Unlike HT-1200 and HT-2500, HT-C3200 is intentionally highly compressible and permanently conforms to mating surfaces under load, with no thickness recovery after compression.

Typical applications include:

  • IGBT and power modules

  • Motor drives and inverters

  • UPS systems and chargers

  • RF power devices and base stations

Nominal thickness: 0.20 mm (0.008”)
Operating temperature range: –40 °C to +400 °C

Thermal Impedance Under Real Clamping Pressure

Thermal impedance—not bulk conductivity alone—determines real-world heat transfer.

Thermal Impedance @ 200 kPa

Material / Thickness Thermal Impedance (K·cm²/W)
HT-1205 (0.005”) 0.59
HT-1210 (0.010”) 0.66
HT-2505 (0.005”) 0.41
HT-2510 (0.010”) 0.58
HT-C3200 0.49

Thermal Impedance @ 700 kPa

Material / Thickness Thermal Impedance (K·cm²/W)
HT-1205 (0.005”) 0.30
HT-1210 (0.010”) 0.40
HT-2505 (0.005”) 0.24
HT-2510 (0.010”) 0.41
HT-C3200 0.18

Design insight:

  • Thickness selection affects impedance within the same material

  • HT-2500 material outperforms HT-1200 at lower clamp forces

  • HT-C3200 delivers the lowest impedance when high pressure is available

Compression & Surface Conformability

Material Compression Behavior
HT-1200 Minimal compression, near-flat surfaces
HT-2500 Moderate compression, lower clamp force
HT-C3200 ~70% compression under high pressure

HT-C3200 is designed to compensate for surface flatness variation, while HT-1200 and HT-2500 prioritize repeatability, stability, and controlled interface thickness.

Why Engineers Choose HITHERM Over Grease or Pads

  • No pump-out or dry-out

  • No burn-in or re-torque cycles

  • Assembly-ready foil format

  • Extremely low outgassing (optics-safe)

  • Stable performance across thermal cycling

  • Precision die-cut parts—clean, repeatable installs

How NEDC Supplies HITHERM Materials

At New England Die Cutting, we supply HITHERM materials from prototype through production, including:

  • Precision die-cut parts

  • Kiss-cut sheets and rolls

  • Laminated constructions with adhesive or dielectric films

  • Support selecting material vs thickness vs clamp force

We focus on engineering fit, not just quoting a part number.

Need help choosing thickness or material?

If you can share clamp pressure, operating temperature, and surface flatness, we’ll help you choose the correct material family and thickness—and cut it to fit.

Datasheet Download HITHERM™

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