Plastolon™ PTFE Unsintered Tape: Validated to ASTM E595 Vacuum Performance and Material Stability Standards
In the vacuum of space, material behavior directly impacts how spacecraft and satellite systems perform over time. Without atmospheric pressure, materials can release trapped gases in a process known as outgassing, which may contaminate optics, interfere with electronics, and reduce long-term system reliability.
Standards such as ASTM E595 – widely used in NASA and aerospace materials screening programs – have become a key benchmark for evaluating how materials perform in vacuum environments. The standard helps engineers assess and select materials that minimize outgassing-related contamination risks, protecting sensitive systems and supporting long-term mission reliability.
The Growing Demands of Space and Satellite Systems
Global investment in space exploration and satellite deployment continues to accelerate. Government-led initiatives such as NASA’s Artemis program, along with ongoing Mars exploration efforts and deep-space missions, are expanding the boundaries of human and robotic spaceflight.
At the same time, commercial space companies are rapidly increasing the number and complexity of satellites in orbit to support communications, earth observation, navigation, and defense applications.
As spacecraft become more compact and systems more densely integrated, material selection is critical to ensuring reliability, contamination control, and long-term performance in orbit.
The Role of PTFE in Space and Satellite Applications
Polytetrafluoroethylene (PTFE) has long been used in space and satellite systems, as well as broader aerospace applications, due to its exceptional chemical resistance, thermal stability, and dielectric properties. In vacuum and extreme temperature environments, these characteristics support stable mechanical and electrical performance.
PTFE is widely specified for applications such as wire harness insulation, conductor wrapping, and insulation of cryogenic lines and valves where outgassing control and long-term reliability are required.
Proven Performance: Evantic Plastolon™ PTFE Unsintered Tapes
For more than 30 years, Evantic’s Plastolon™ PTFE Unsintered Tapes (also known as extruded, unstretched tapes) have been trusted for high-performance wire and cable applications requiring precision, consistency, and durability. These tapes are recognized for exceptional color consistency, uniform material properties, and superior electrical performance, including excellent arc resistance.
Additional performance characteristics include:
- Reliable flexural strength for convoluted hoses and control cables
- Exceptional chemical resistance for harsh environments
- Superior dielectric properties for electrical insulation
- Extreme temperature stability from cryogenic conditions up to 500°F (260°C)
- High dimensional stability through precision calendering and tight tolerances
- Low friction and non-stick performance for smooth mechanical movement
- Lightweight construction for reduced system mass
- Market-leading uniformity across every roll
Plastolon™ PTFE Unsintered Tapes also meet stringent industry standards, including ASTM D6585, AS22759, MIL-STD-104, and EIA-339-A, making them suitable for critical aerospace, defense, and advanced electronics applications.
They are available in standard and specialty colors for identification and application-specific requirements. All color formulations are compliant with RoHS, REACH, and California Proposition 65 standards.
Outgassing Performance Verified for Space Applications
Evantic’s Plastolon™ PTFE Unsintered Tapes have been independently tested in accordance with ASTM E595 to validate performance in vacuum environments.
ASTM E595 is used to evaluate how materials behave in space-like vacuum conditions by measuring Total Mass Loss (TML), Water Vapor Regained (WVR), and Collected Volatile Condensable Materials (CVCM). These values are critical in determining whether a material is suitable for use near sensitive systems such as optics, sensors, and electronic assemblies.
The test results are summarized below for Plastolon™ PTFE Unsintered Tape samples evaluated under ASTM E595 conditions.
ASTM E595 Outgassing Test Results for Plastolon™ PTFE Unsintered Tape Samples
| Parameter | White Tape Sample | Green Tape Sample |
|---|---|---|
| Total Mass Loss (TML) % | 0.02 | 0.02 |
| Water Vapor Regained (WVR) % | 0.00 | 0.00 |
| Collected Volatile Condensable Materials (CVCM) % | 0.01 | 0.02 |
Full ASTM E595 test data and supporting documentation available upon request.
Results and Interpretation
Both samples, White Tape and Green Tape, demonstrated Total Mass Loss (TML) values of 0.02%, well below the ASTM E595 screening threshold of 1%.
Collected Volatile Condensable Materials (CVCM) results measured 0.01% and 0.02%, respectively, also significantly below the allowable limit of 0.1%. Water Vapor Regained (WVR) measured 0.00% for both samples, indicating negligible moisture absorption during the post-test recovery period.
Together, these results indicate strong compliance with ASTM E595 requirements, supporting reliable performance in space systems where contamination control is critical.
“As satellite and space systems evolve, material performance becomes a defining factor in what missions can achieve.”— Rodrigo Costa, Director of Engineering, Evantic
Ideal Applications
- Spacecraft wire harness insulation and conductor wrapping
- High-speed data cable insulation in satellite payloads
- Wiring in proximity to optical sensors, mirrors, and imaging arrays
- Cryogenic line and valve insulation in launch vehicle propulsion
- Defense avionics wiring in vacuum-sensitive or sealed enclosures
- Wire and cable assemblies requiring NASA/ESA outgassing qualification
The Plastolon™ Difference
Evantic’s manufacturing approach focuses on delivering application-ready PTFE tape solutions with consistent convertibility, customization, and production efficiency:
- Long splice, defect-free lengths for uninterrupted processing
- Custom slit widths and specialized thickness options to support application requirements
- Multiple color options with superior uniformity for identification and traceability
- Engineered formulations tailored to performance demands
- Packaging configurations designed to improve handling and production flow
- Laser-markable tape with high-contrast readability for system identification
Supporting the Future of Space Systems
As space systems continue to evolve in complexity and capability, material selection becomes increasingly critical to mission success. Engineers require solutions that not only meet established standards but also deliver consistent performance under extreme environmental conditions.
With independently verified ASTM E595 performance and decades of proven reliability, Evantic’s Plastolon™ PTFE Unsintered Tapes provide the confidence needed for today’s most demanding aerospace and satellite applications.
Learn More
For complete PTFE Unsintered Tape specifications, including thickness, width range, lengths, tensile strength, dielectric strength, and color options, download the Plastolon™ PTFE Tapes & Films Brochure.
This post was contributed by Rodrigo Costa, Director of Engineering, Evantic.