Introduction
Managing heat in electronics is one of the toughest challenges engineers face. As devices get smaller and more powerful, thermal performance becomes critical. Tflex™ 50000, a gap filler from Laird, is designed to efficiently conduct heat while protecting sensitive components. At New England Die Cutting (NEDC), we take this advanced material and make it practical for real-world designs by die-cutting it into precise, application-ready parts.
What Is Tflex™ 50000?
Tflex™ 50000 is a soft, silicone-based thermal gap filler with excellent compliance and high thermal conductivity. It bridges uneven gaps between heat-generating components and heat sinks or enclosures, ensuring reliable thermal transfer.
Key specifications include:
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Thermal Conductivity: ~2.8 W/m·K
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Thickness Range: 0.5 mm to 5.0 mm (in 0.25 mm increments)
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Hardness: Shore 00 ~40
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Density: ~3.0 g/cc
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Thermal Resistance @ 10 psi: ~0.397–1.720 °C-in²/W
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Temperature Range: –50 °C to +200 °C
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Flammability Rating: UL 94 V-0
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Outgassing: TML ~0.29%, CVCM ~0.04%
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Shelf Life: 2 years from shipment
Tflex™ 50000’s natural tackiness allows it to stay in place without adhesives, and its softness means minimal stress on components during compression.
Applications
Engineers rely on Tflex™ 50000 across many industries:
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Aerospace & Defense – avionics, satellites, and rugged military electronics.
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Automotive – ADAS modules, infotainment, and electric vehicle control units.
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Consumer Electronics & Telecom – laptops, gaming systems, routers, and base stations.
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Industrial & Portable Devices – drones, sensors, and IoT devices.
Wherever high power density, and small form factors meet, Tflex™ 50000 delivers consistent thermal management.
Notice: Sub-1 mm Versions Being Discontinued
Laird has announced that Tflex™ 50000 sheets under 1 mm thickness will be discontinued:
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End-of-sale: December 31, 2025
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Final orders accepted: January 30, 2026 (subject to available stock)
Recommendation for New Designs
While Tflex™ 50000 remains widely used, new designs should transition to Tflex™ HD300, a next-generation gap filler that delivers improved thermal performance and better handling characteristics. By specifying HD300 in new projects, engineers future-proof their designs against material phase-outs while maintaining top-tier performance.
Where NEDC Comes In: Custom Die-Cutting
While Tflex™ 50000 is supplied in sheets, most applications require specific geometries. At NEDC, we provide:
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Custom die-cut parts to exact dimensions for your assembly.
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Kiss-cutting on release liners for easy peel-and-stick handling.
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Adhesive-backed options when additional mounting security is needed.
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Scalable production — from prototypes to high-volume runs.
Because Tflex™ 50000 is soft and tacky, it can be challenging to process. As a Laird converter, NEDC has the expertise and direct partnership to supply clean, accurate die-cut parts with consistent quality — ensuring customers get both trusted material and precision fabrication.
Summary: Tflex™ 50000 + NEDC Die-Cutting = Complete Thermal Solution
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Tflex™ 50000 offers excellent thermal conductivity (2.8 W/m·K), flexibility, and reliability.
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Available in 0.5 mm to 5 mm thicknesses, stable from –50 °C to +200 °C, and UL 94 V-0 rated.
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Sub-1 mm versions are being phased out — plan accordingly.
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New designs should use Tflex™ HD300 for long-term supply chain security, and improved performance.
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NEDC, as an approved Laird converter, die-cuts this material into ready-to-use shapes that save time and improve integration.
Conclusion
Tflex™ 50000 is one of the most versatile thermal gap fillers available today, balancing thermal performance, mechanical compliance, and ease of use. With NEDC’s die-cutting expertise and status as a Laird converter, customers get not just raw sheets, but precision-engineered parts tailored to their designs — from prototype to production scale. And for new projects, Tflex™ HD300 is the smart choice moving forward.