Common film thicknesses used for foil balloons include 0.023 mm, 0.025 mm, 0.027 mm and 0.029 mm. Thickness influences feel, forming behavior, durability, sealing and cost, but it should never be considered without film construction and product design.
Practical size guidance
| Balloon size | General manufacturing guidance |
|---|---|
| Up to 35 cm | 0.023–0.027 mm may be evaluated depending on design and use. |
| Over 35 cm | Use at least 0.027 mm as a general recommendation. |
| Over 80 cm | 0.029 mm is recommended. |
These are manufacturing guidelines, not a substitute for prototype and performance validation. Narrow sections, sharp transitions, deep forming, helium use, hanging loads and long distribution cycles can justify a stronger construction.
How to specify thickness
Record the nominal thickness in millimetres, the laminate structure, acceptable tolerance if applicable, balloon dimensions, inflation method and test conditions. Confirm the measurement method with the supplier when thickness is a critical requirement.