A Breakdown of Foam Tape Thicknesses: Which One Should You Use?

Foam tape is a pressure-sensitive adhesive made of foam combined with materials such as PVC, silicone, PE, or acrylic depending on its function. Available in both single and double-sided forms, foam tape is highly versatile thanks to the range of lengths, widths, thicknesses, and colours it comes in. It’s used across multiple industries because it adheres well to both smooth and uneven surfaces.

In this article, we’ll explore different foam tape thicknesses and the factors to consider when choosing the right one for your project.

Single-Sided or Double-Sided?

Single-sided foam tape is ideal for sealing and anti-slip applications. It compresses to create effective seals against air, dust, and moisture.

Double-sided foam tape is more commonly used for mounting and bonding. It distributes stress well between materials, making it suitable for joining materials with different thermal expansion rates.

Choosing the Right Thickness

The thickness of foam tape directly impacts its performance. Here are five key considerations:

1 – Compression & Conformability

• Thin tapes (0.5–1.0mm) work best on smooth, rigid surfaces.
• Medium tapes (1.0–2.0mm) balance flexibility and strength, adapting to lightly textured surfaces.
• Thick tapes (2.0mm+) conform to rough or uneven surfaces, filling gaps effectively.

2 – Load-Bearing Capacity

Thinner tapes provide higher static shear resistance, making them better for vertical load-bearing or hanging applications. Thicker tapes, while good at cushioning, can creep under prolonged loads.

3 – Shock Absorption & Vibration Damping

For environments with heavy vibration or impact, thicker tapes excel. Their cushioning properties absorb shocks and reduce long-term wear on bonded materials.

4 – Bonding Strength Over Irregular Gaps

Thicker tapes are ideal for filling unavoidable gaps caused by uneven surfaces or manufacturing variations. They flex to bond securely while maintaining strength.

5 – Thermal Insulation & Weather Sealing

Thicker foam tapes provide better insulation and protection from the elements. They are commonly used in window glazing, outdoor signage, and HVAC systems where resistance to moisture and air penetration is essential.

Conclusion and Final Advice

Choosing the right foam tape thickness depends on your materials, surface conditions, and the type of stresses involved. In summary:

• Match tape thickness to surface smoothness and gap size.
• Use thinner tapes for vertical loads and higher static resistance.
• Choose thicker tapes for cushioning, vibration control, or weather sealing.
• Test adhesives in small-scale trials before full application.

For expert guidance, Bricon Industries is here to help. As one of Australia’s leading foam tape suppliers, we bring extensive experience in fastenings for roofing and beyond. Reach out to our friendly team today and let us help you choose the best foam tape for your needs.