0.0045mm Ultra-thin Aluminum Foil

0.0045mm ultra-thin aluminum foil — leading a new era of micron- level materials

As aluminum foil manufacturing tends to be micron-level and extremely thin, Chalco has successfully broken through the industry limit and was the first to achieve stable mass production of ultra-thin aluminum foil with a thickness of only 0.0045mm (4.5μm) , breaking the global record for aluminum foil thickness. This thickness is only 1/20 of a hair and is a technological upgrade of the current mainstream 6-9μm aluminum foil on the market.

This product not only has extremely high flexibility and ductility, but also has excellent surface cleanliness, thermal conductivity and composite compatibility, providing core basic materials for a variety of high-precision processes such as pharmaceutical packaging, battery electrodes, conductive shielding, high-end label films, etc.

Chalco 0.0045mm ultra-thin aluminum foil product technical parameters and material specifications

To meet the stringent requirements of high-end precision technology, Chalco's 0.0045mm ultra-thin aluminum foil has reached the industry's advanced level in terms of material purity, thickness control, surface treatment and processing adaptability. The following are the basic technical parameters of this product:

Thickness range: 0.0045 mm (±0.0002 mm)

Alloy options: 1235-O, 8079-O, 8011-O

Delivery temper: O (soft state)

Maximum width: 1000 mm (custom cutting is supported)

Surface treatment options: degreasing/mirror finish/single-sided roughening/hydrophilic coating/color printing coating/conductive coating, etc.

Coil inner diameter: φ76 mm / φ152 mm

Delivery form: Coil (standard) / Cut-to-length pieces / Die-cut pieces / Multi-layer composite substrates available

Thickness control accuracy: ±0.2 μm (guaranteed by full-line tension closed-loop control system)

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Note:

• The surface cleanliness meets the pharmaceutical and food grade standards and is suitable for solvent-free coating, dry lamination, heat-sealing lamination and other processes;
• Its extreme thinness makes it very suitable for conductive coating films, electrode sheets, and EMI composite structures that require high conductivity/lightweight structures;
• It supports sample rewinding, customization of width/tension/ roll diameter, and adapts to the usage rhythm of customers' precision processing lines.

Chalco 0.0045mm ultra-thin aluminum foil performance advantages overview

Chalco's 0.0045mm ultra-thin aluminum foil not only leads the industry in thickness control, but also demonstrates comprehensive advantages far exceeding traditional aluminum foil in terms of mechanical properties, surface state, functional compatibility and processability. The following are the five core performance advantages of this product:

Extremely thin and light, high thickness accuracy: Aluminum foil thickness reaches 0.0045mm (±0.2μm control), supports large roll supply, reduces unit weight, and improves the lightweight degree of composite structure

Strong flexibility and no brittle cracking: After special annealing treatment, it is soft and not easy to crack, suitable for bending, embossing, winding and other scenes ; in high-speed lamination and molding processes, it shows excellent processability stability

Clean surface and compatible functions: controllable surface tension, clean and oil-free ; compatible with heat sealant, water glue, carbon slurry, conductive film, thermal conductive film, color printing ink and other materials

Strong structural adaptability: adaptable to a variety of composite methods (dry composite/coating composite/multi-layer calendering, etc.) ; supports collocation with PET, paper, PE, foam, conductive film and other materials

High stability and traceable production: The whole process is digitally controlled, and the difference between batches is minimal ; factory documentation support such as thickness records, tension curves, and cleanliness testing can be provided

Six high-end application scenarios of Chalco 0.0045mm ultra-thin aluminum foil

As the manufacturing industry's dual demands for "lightweight + high performance" materials continue to increase, ultra-thin aluminum foil is becoming a new focus of precision composite structures and functional packaging materials in multiple industries.

Relying on the full-process aluminum manufacturing system and ultra-thin rolling control capabilities, Chalco's 0.0045mm (4.5μm) aluminum foil product breaks the thickness bottleneck of traditional rolling technology and achieves performance breakthroughs in key areas such as pharmaceutical packaging, food packaging, new energy batteries, EMI shielding, and electronic capacitors.

Ultra-thin aluminum foil for pharmaceutical packaging (PTP, heat seal layer)

In structures such as pharmaceutical blister packaging (PTP) and small-dose sealing films, aluminum foil is in direct contact with the drug, and has extremely high requirements for thickness, softness, and cleanliness. With the trend of environmental protection and the growing demand for small packages, traditional 6-9μm aluminum foil has gradually failed to meet the needs of efficient packaging lines and lightweight packaging.

• Lighter and thinner: Reduce the thickness and weight of unit packaging, improve logistics efficiency and environmental performance
• Strong softness: suitable for high-precision blister molds, good molding, not easy to burst
• Large roll supply capability: Longer rolls are suitable for high-speed packaging lines, reducing frequent roll changes
• Medical grade clean surface: The cleanliness reaches medical grade, suitable for a variety of heat sealing coatings and printing processes
• Chalco supporting capabilities: support for process collaborative customization such as fixed-width cutting, pretreatment, color printing and coating

Ultra-thin aluminum foil for cigarette and food packaging

In fast-moving consumer goods packaging such as cigarette linings, candy packaging, and tea packaging, aluminum foil needs to have barrier properties, gloss, and flexibility. 0.0045mm aluminum foil can greatly improve the packaging aesthetics and structural flexibility, making it an ideal choice for high-end consumer brands.

• The packaging is more compact and thinner: the extremely thin thickness reduces the structure stacking and improves the packaging texture
• Excellent processing compatibility: soft and docile, suitable for cold stamping, embossing, hollowing and other decorative processing
• Increased coil length: Adapt to automatic lamination and labeling equipment to reduce line downtime
• Multi-layer composites : supports composites with PET, paper, printed films, etc.
• Chalco delivery advantages: can provide fixed width, fixed length cutting, lamination/gluing and other processing forms

Ultra-thin aluminum foil for battery carbon-coated current collector

In soft-pack lithium batteries and sodium-ion battery negative electrodes, aluminum foil is used as the current collector base material, which has extremely high requirements for thickness accuracy and conductive surface treatment. 0.0045mm ultra-thin aluminum foil helps improve energy density and winding compactness, and is an ideal choice for the next generation of high specific energy battery cell structures.

• Thinner and lighter structure: significantly reduce the thickness of the pole piece and increase the energy density per unit volume
• Excellent winding compactness: thinner and softer, suitable for high-density stacking module design
• Good compatibility of carbon slurry coating: clean and oil-free, stable tension, suitable for carbon layer adhesion
• Strict thickness tolerance control: error ≤ ±0.2μm, supporting high-speed automatic production line
• Chalco supports customized development: composite PET layer, conductive coating, surface roughening and other processes

Capacitor pole piece and microelectronic functional structure

In high-frequency fields such as aluminum electrolytic capacitors, thin film capacitors, and microelectronic functional film layers, ultra-thin aluminum foil has become one of the core materials for small high-capacitance components and new functional composite films due to its excellent windability, dimensional consistency, and low resistance characteristics.

• Reduce device size: Thin foil structure achieves higher capacitance ratio, more suitable for small capacitor modules
• Strong surface treatment compatibility: supports pre-treatment processes such as anodizing, electrolytic etching, and roughening
• Excellent cable arrangement and winding performance: suitable for automatic cable arrangement equipment to reduce winding stress
• Structural consistency guarantee: Minimal differences within and between rolls, improving electrical consistency of finished products
• Chalco in-depth support: support customers to formulate surface conditions, pre-etching/non-etching specifications, batch traceability

EMI shielding & thermal control composite structure

Electronic packaging, electric vehicle battery modules, aviation thermal control systems and other fields have higher requirements for flexibility, reflectivity and adhesion of structural laminated foils. 0.0045mm ultra-thin aluminum foil is used as a conductive/heat-reflective intermediate layer, which has better fit and material integration space.

• Lighter shielding structure: Reduce the number of layers and total thickness, and enhance material integration capabilities
• Softer and more adaptable: suitable for multi-media lamination such as curved surface structure and composite conductive film
• Improve thermal reflectivity and heat dissipation path efficiency
• Adapt to the composite requirements of EMI functional films: can carry composite structures such as conductive glue, foam, PET film, etc.
• Chalco stable supply guarantee: support high roll length, high cleanliness, fixed tension process parameter delivery

New material application research and development/ brazing structure exploration

Ultra-thin aluminum foil is also being gradually introduced into more cutting-edge functional composite fields, such as multi-layer brazing structures, aviation heat exchangers, thermal control shells, etc. Chalco is conducting brazing performance tests with alloy layers such as 4343 and 7072, and is jointly developing ultra-thin composite structures with scientific research customers.

• Adapting to the new multi-layer brazing structure design: Improving the lightweight and thermal efficiency of the composite thermal control panel
• Support trial batch and proofing test: coil size/performance can be flexibly matched with scientific research and development needs
• The material system is scalable: composite laminate structures can be developed with 4343/7072, etc.
• Chalco technical team collaborates in development: Brazing parameter verification and coating and formability research

If you need more professional industry customized matching suggestions, please contact us for structural design support and composite solution guidance. Quick Quote

Chalco ultra-thin aluminum foil production capabilities and customization services

In order to achieve a stable batch supply of 0.0045mm ultra-thin aluminum foil, Chalco has established a highly integrated ultra-thin foil manufacturing platform, covering aluminum foil billet smelting, finishing rolling control, tension coiling, online detection and deep processing adaptation processes, supporting a variety of specifications, processing states and coil delivery solutions.

Customized service highlights

• Thickness/width customization: Supports precise control of thickness (±0.2μm) and slitting width (±0.5mm) as required
• Collaborative development of composite structures: We can provide material selection suggestions and adaptive design in cooperation with customers’ composite structures
• Optional functional treatment: Anodic treatment, electrophoresis, carbon coating, punching, anti-static and other special treatments are available
• Support proofing and small batch ordering: provide proofing test rolls, performance test reports, and stable traceability codes
• Flexible delivery and export compliance: fast delivery within 3-10 working days, compliant with RoHS, REACH, GB/T and other standards

FAQ

How is 0.0045mm aluminum foil better than regular aluminum foil?

Compared with traditional 6-9μm aluminum foil, Chalco 0.0045mm aluminum foil performs better in softness, unit weight, composite compatibility and high-speed processing efficiency. It is particularly suitable for high-precision and lightweight scenarios such as small-dose packaging of pharmaceuticals, battery electrodes, EMI film materials, etc.

Is such thin aluminum foil prone to breaking or cracking?

No. Chalco uses a special annealing and tension control process to ensure that the aluminum foil is soft and rollable without cracking, suitable for high-speed packaging lines, heat sealing equipment, embossing and die-cutting processes, etc.

Is it possible to compound materials such as PET, paper, and conductive film?

Yes. This series of aluminum foil supports multiple processes such as dry lamination, coating, hot pressing, etc., and can be combined with different materials such as BOPP, PET, kraft paper, foam, conductive film, carbon film, etc. to form a multi-layer functional structure.

Can you customize the size, core or surface?

Yes. We can provide fixed width and fixed length cutting, with aluminum core/ paper core coils; we also support anodizing, electrophoresis, heat seal coating, anti-static treatment and other functional processing.

Can it be used for special applications such as brazing, carbon slurry coating, capacitor electrodes, etc.?

Some areas are already being verified. Chalco is working with multiple industries to develop multifunctional application solutions for ultra-thin aluminum foil in the fields of brazing layer, negative electrode current collector, EMI layer, etc., and can assist in matching performance indicators according to customer process paths.

Can you provide samples? What is the minimum order quantity?

We can provide test rolls or small batch samples, and the thickness tolerance of conventional samples is ≤±0.2μm. MOQ can be flexibly negotiated according to different product forms and delivery methods.

Are test reports and compliance documents provided?

Chalco can provide factory documents such as thickness testing, tension records, cleanliness reports, etc. along with the goods, and support ISO, GB/T, RoHS, REACH and other standard certification requirements.

If you need further technical consultation or submit drawing parameters, please click the button below to get solution suggestions or apply for sample trial production.

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