Mylar® (PET polyester) film is a clear, dimensionally stable plastic with excellent strength-to-weight ratio, moisture resistance, and electrical insulation properties. It’s commonly used for insulation, stencils, overlays, shims, labels, and lightweight mechanical components where clarity, precision, and durability are essential.
Instant quote
A: .5″ x .5″
B: 23″ x 47″
Custom quote
C: 23″ x 47″
.005″ (.127mm)
.010″ (.254mm)
Mylar® is a biaxially-oriented PET polyester film known for its clarity, stiffness, and electrical insulation. It resists moisture and many chemicals, offers excellent dimensional stability, and maintains properties across a wide temperature range.
This material shows up everywhere, from the shop floor to custom DIY builds. Here are a few ways makers and engineers put it to work every day.
We guarantee awesome quality parts. If you’re not 100% happy, we’ll give you a refund or remake on the spot – no questions, no hassle.
SendCutSend offers Mylar Clear in two thickness options: .005″ (.127mm), and .010″ (.254mm).
When ordering Mylar Clear through SendCutSend, there are specific size and thickness parameters to keep in mind. For instant quoting, the smallest part size available is .5″ x .5″, while the largest part supported is 30″ x 44″.
No additional services are available for Mylar Clear cut parts.
We accept .ai, .dxf, .dwg, .eps, .stp, and .step
Customize one of our simple parts templates
Clear Mylar film, commonly made from PET polyester, is known for its exceptional dimensional stability, clarity, chemical resistance, and durability despite its extremely thin gauge. Designers, engineers, hobbyists, and fabricators choose Mylar when they need a material that is thin, flexible, tear-resistant, and dimensionally stable, making it ideal for everything from electrical insulation to stencils, templates, optical components, packaging, and protective overlays. At SendCutSend, we laser cut clear Mylar sheets in .005” and .010” thicknesses to ±.009” tolerance, allowing customers to create precise patterns, spacers, insulating components, and lightweight parts with extremely thin geometries.
These traits make Mylar one of the most reliable thin-film materials available for precision work.
Fabricators reach for Mylar when they need a material that stays flat, stable, and flexible but doesn’t stretch, distort, or tear easily. It behaves more like a durable engineering film than a fragile plastic sheet. Professionals choose Mylar because:
Where typical films fail, by stretching, cracking, or deforming, Mylar remains stable and reliable.
Unlike many thin plastics, Mylar holds its shape under stress. It won’t stretch, deform, or warp under normal use, which is why it’s widely used for:
Its stability gives it a level of repeatability that other films can’t match.
Even at .005” and .010”, Mylar resists tearing and puncturing. This makes it far more durable than PVC or polypropylene films.
Mylar stands up to:
This is why it’s used in electrical insulation, lab environments, and packaging.
Clear Mylar is ideal for viewports, protective lenses, instrument covers, and overlays where you need high visibility and protection without weight.
Laser cutting Mylar results in:
No charring, melting, or discoloration.
Mylar is thin and flexible — it cannot support weight or act as a structural material. For rigid transparent materials, consider:
High temperatures can cause shrinkage or distortion. Avoid:
Because Mylar is only available in .005” and .010”, it isn’t suitable for applications requiring stiffness or thicker sections.
As a clear film, Mylar can scratch over time, especially in abrasive environments.
Mylar can hold static charges, which may attract dust or debris. Clean handling is recommended for optical or cosmetic applications.
Mylar responds extremely well to laser cutting. Its thin gauge and stable film structure produce excellent results.
Laser cutting is the best method for cutting Mylar. Mechanical methods can cause stretching or tearing, while lasers maintain perfect geometry.
Because Mylar is flexible, very small geometry can behave differently than in rigid plastics:
If precision is critical, choose the .010” thickness for added stability.
Designing for Mylar requires accounting for its flexibility, thinness, and tendency to bend under handling.
Avoid tiny slots, hooks, or tabs, especially in .005”.
Fillets reduce stress and avoid tear initiation points.
Sharp corners can act as tear starters in thin film.
Because Mylar flexes, slightly oversized holes reduce wrinkling or stress.
Design parts that won’t kink or fold easily during use.
Thicker film has greater durability and precision for repeat use. For more guidance: SendCutSend’s design guidelines
Clear Mylar is widely used anywhere precision film, clarity, and durability are important. Common applications include:
Mylar is especially valued in industries requiring repeatability, durability, and transparency in very thin material.
Choose clear Mylar when your design requires a thin, stable, flexible, clear film that can handle repetitive stress without tearing. It’s ideal for lightweight overlays, stencils, precision film parts, insulating components, and templates that need to be durable and dimensionally reliable. Mylar is right for your project if you need:
At SendCutSend, we laser cut clear Mylar in .005” and .010” thicknesses to ±.009” tolerance, giving you high-precision, ready-to-use components with 2–4 day lead times.
