Comprehensive Technical Analysis of High-Performance Special Films: PPS vs. PAEK

In the field of high-end specialty films, PPS (Polyphenylene Sulfide) film and PAEK (Polyaryletherketone) film are widely utilized high-performance thermoplastic materials. Leveraging their exceptional high-temperature resistance, electrical insulation, and chemical stability, both products have become core substrates for aerospace, high-end electronics, and the new energy industries. Due to differences in their molecular structures, substantial variations exist in their core performance, application scenarios, production processes, and comprehensive cost structures.

Based on extensive mass-production and R&D expertise, Shanghai Harsom Advanced Materials Co., Ltd., a domestic leader in PPS film, presents this systematic analysis. This report details the core differences, application boundaries, production capacities, technological advantages, and selection logic of PPS and PAEK films, serving as a professional and actionable material selection reference for industry clients.

I. Molecular Structure and Core Definition: Root Differences in Architecture

(A) PPS Film (Polyphenylene Sulfide Film)

PPS is a linear high-molecular-weight polymer formed by alternating benzene rings and sulfur atoms. Its highly regular molecular structure and high crystallinity impart both rigidity and thermal stability. Manufactured through cast or biaxially-oriented (BOPPS) processes, PPS film stands as the mainstream choice for mid-to-high-end specialty insulation films, recognized for its "high cost-performance ratio + stable high performance."

(B) PAEK Film (Polyaryletherketone-based Film)

PAEK represents a class of aromatic polymers featuring ether linkages (-O-) and ketone carbonyl groups (-CO-) as core repeating units, with prominent variants including PEEK (Polyetheretherketone) and PEKK (Polyetherketoneketone). The stable conjugated aromatic benzene rings within its molecular structure endow it with ultra-high heat resistance, exceptional mechanical strength, and extreme weatherability. Positioned as an ultra-high-end specialty film, its performance benchmarks against PI (Polyimide) film, yet it offers superior thermoplasticity and recyclability.

II. Core Performance Comparison: PAEK Leads Overall, PPS Excels in Cost-Efficiency

(A) Key Performance Metrics (Critical Client Considerations)

(B) Summary of Core Performance Differences

1.Thermal Tiering: PAEK film operates at a temperature tier 30–40°C higher than PPS film. It runs stably at 250°C+ for long periods and can withstand short-term exposure above 300°C, making it ideal for ultra-high-temperature scenarios like aerospace engines and semiconductor manufacturing. PPS film remains stable at 220°C long-term, satisfying standard high-temperature demands in new energy vehicles (NEVs) and high-end electronics.

2.Environmental Stability: PAEK film exhibits ultimate resistance to hydrolysis, radiation, and chemical exposure, showing virtually zero performance degradation under high humidity, corrosive, or high-radiation environments. While PPS film offers excellent stability, its performance drops slightly under extreme conditions (e.g., 100°C boiling water or intense radiation).

3.Mechanical Strength: PAEK film boasts higher tensile strength along with superior tear and impact resistance, suiting lightweight structural components and high-strength insulation. PPS film provides sufficient mechanical strength for standard industrial applications at a much lower cost.

4.Cost Positioning: PPS film targets "mid-to-high-end rigid demands," delivering compliant performance at a moderate price. PAEK film is positioned for "ultra-high-end, cutting-edge applications" where ultimate performance is non-negotiable despite its premium pricing.

III. Application Scenarios: PPS Focuses on Mainstream Premium, PAEK Targets Cutting-Edge Niches

(A) PPS Film: Mainstream Workhorse Covering New Energy, Electronics, and Industry

1. High-End Electronics (Core Scenario)Applications: Insulation layers for 5G/6G base station FPCs, coverlays for foldable smartphone FPCs, and high-frequency circuit board substrates.Value Proposition: Available in ultra-thin specifications (6–25 $\mu$m) with low dielectric properties and excellent dimensional stability. It optimizes high-frequency, high-speed signal transmission while reducing signal loss at only 1/3 the cost of PI film.
2. New Energy Vehicles (Fastest-Growing Scenario)Applications: Power battery insulation gaskets, motor insulation systems, battery pack fireproof insulation layers, and high-temperature sensor substrates.Value Proposition: 220°C heat resistance, UL94 V-0 flame retardancy, and hydrolysis resistance ensure automotive-grade safety under harsh operating conditions.
3. Industrial & Electrical ApplicationsApplications: Transformer/motor insulation, industrial tape substrates, high-temperature electronic tags, and capacitor films.Value Proposition: High insulation, low water absorption, and controllable costs allow it to replace traditional PET and PI films, driving cost reduction and efficiency gains.
4. Aerospace (Entry-Level)Applications: Airborne electronic equipment insulation and lightweight cable wrapping.Value Proposition: Replaces low-end imported PPS films, achieving a 30% weight reduction at a lower cost than PI film.

(B) PAEK Film: Absolute Requirement for Cutting-Edge Fields Covering Aerospace, Medical, and Semiconductors

1. Aerospace (Core High-End Scenario)Applications: Aero-engine peripheral insulation, lightweight structural parts, high-temperature cable insulation, and airborne radar high-frequency substrates.Value Proposition: Long-term heat resistance at 250°C+, high radiation resistance, and lightweight characteristics. It replaces metals and PI films to achieve a 40%+ weight reduction, adapting perfectly to extreme high-altitude environments.
2. Medical & Healthcare (High-Value-Add Scenario)Applications: Medical catheters, implantable films (e.g., orthopedic repair membranes), and surgical instrument protective wraps.Value Proposition: Medical-grade biocompatibility, non-toxic, and resistant to repeated sterilization (high-temperature steam/ethylene oxide). It is X-ray transparent, making it ideal for human implants and sterile medical environments.
3. Semiconductor & Precision ElectronicsApplications: Protective films for high-temperature semiconductor manufacturing, chip packaging insulation substrates, and core insulation layers for high-frequency millimeter-wave radars.Value Proposition: Low dielectric constant, high thermal resistance, and exceptional chemical stability. It withstands 250°C+ semiconductor processes, enhancing chip reliability.
4. Extreme Industrial EnvironmentsApplications: Oilfield high-temperature sensors, chemical equipment anti-corrosion insulation, and nuclear industry radiation shielding films.Value Proposition: Resists extreme heat, harsh corrosion, and heavy radiation. Its lifespan far exceeds that of PPS film, significantly lowering equipment maintenance costs.

IV. Capacity & Technical Overview: PPS Domestic Maturity, PAEK High-End Breakthroughs

(A) PPS Film: Ample Domestic Capacity, Technology Benchmarked Against Imports

1. Capacity Status (As of 2026, China)Leading Enterprises: Harsom Advanced Materials (annual capacity of 3,940 tons of ultra-thin PPS film, primarily focusing on 6–25 $\mu$m), Zhejiang NHU (annual capacity of 35,000 tons with integrated resin-to-film production), Shenzhen Yutian New Materials, and Suzhou Yuemo New Materials.Market Dynamics: Low-to-mid-end capacity faces oversupply, whereas high-end ultra-thin (6–12 $\mu$m) capacity remains scarce. Harsom Advanced Materials is currently the only domestic enterprise capable of commercial mass-production of 6–12 $\mu$m ultra-thin PPS film, filling a critical domestic gap.
2. Core TechnologiesUltra-Thin Casting Technology: Resolves the challenges of film breakage and thickness non-uniformity in the 6–12 $\mu$m range, maintaining thickness tolerances within $\pm0.5 \mu$m.Biaxial Stretching Technology: Employs closed-loop control of stretching parameters to boost dimensional stability (thermal shrinkage $\le0.5\%$ @ 200°C).Modification Technology: Utilizes nano-filler modifications to lower the dielectric constant to 3.0, tailoring the material for high-frequency applications.

(B) PAEK Film: Scarce Capacity, High Technical Barriers, Accelerated Domestic Substitution

1. Capacity Status (As of 2026, Global & Domestic)Global Giants: Victrex (UK, holding a global monopoly on PEEK film), Solvay (Germany), and Mitsui Chemicals (Japan).Domestic Breakthroughs: Harsom Advanced Materials (the first domestic company to achieve mass production of PAEK film, complementing its PPS film portfolio, targeting aerospace and medical grades) and Jilin Zhongyan High Polymer (PEEK resin + film).Market Dynamics: Global production capacity is highly limited, and domestic supply is constrained. The technical barriers for PAEK film are steep, with equipment and processes historically dependent on imports. Only a select few enterprises have mastered mass-production techniques.
2. Core TechnologiesPolymerization Technology: Independent synthesis of high-purity PAEK resin (PEEK/PEKK), with precise control over molecular weight distribution to guarantee film-forming stability.High-Temperature Film Forming: Since PAEK has a melting point above 340°C, dedicated high-temperature casting/stretching equipment is required, maintaining temperature accuracy within $\pm1$°C to prevent thermal degradation.Purification Technology: Medical-grade PAEK film demands rigorous impurity control to achieve a purity of 99.9%, satisfying stringent biocompatibility requirements.

V. Selection Logic: Matching Requirements to Balance Performance, Cost, and Supply Chain

(A) Scenarios Factoring PPS Film First

1. Operating temperatures $\le220$°C, cost-sensitive projects, and a need for high-volume, scalable supply.

2. 5G FPCs, new energy vehicle battery/motor insulation, and industrial electrical insulation.

3. Applications pursuing high cost-efficiency to replace low-to-mid-end imported PPS or PI films.

(B) Scenarios Factoring PAEK Film First

1. Operating temperatures $\ge250$°C or extreme working conditions (strong corrosion, severe radiation, or medical implants).

2. Aero-engine components, high-temperature semiconductor processing, and human-implantable medical devices.

3. Applications where performance cannot be compromised, budgets are sufficient, and long-term operational stability is critical.

(C) Strategic Recommendations for Domestic Substitution

1. For PPS Film: Prioritize domestic leaders such as Harsom Advanced Materials and NHU. Their performance benchmarks directly against international brands like Toray and Solvay, while offering a 20%–30% cost reduction and stable lead times.

2. For PAEK Film: For small-batch, high-end requirements, choose Harsom Advanced Materials (the first domestic mass producer) to replace imported brands like Victrex. This strategic switch shortens delivery cycles from 4–8 weeks down to 2–4 weeks and reduces procurement costs by over 30%.

VI. Strategic Summary of High-Performance Specialty Films

While both PPS and PAEK films belong to the high-performance thermoplastic specialty film category, they diverge significantly in positioning, performance, applications, and cost:

PPS film serves as the mainstream mid-to-high-end choice. With a heat resistance of 220°C and excellent cost-efficiency, it captures rigid demands across new energy, high-end electronics, and industrial sectors, backed by mature domestic capacity and stable technology.PAEK film represents the ultra-high-end, cutting-edge choice. Featuring extreme heat resistance of 250°C+ and ultimate material properties, it monopolizes irreplaceable applications across aerospace, medical, and semiconductor sectors. Rapid domestic technological breakthroughs are now accelerating its import substitution.

Looking ahead, as high-end manufacturing continues to upgrade, PPS film will expand its market penetration within new energy and electronic sectors. Concurrently, PAEK film will steadily realize domestic substitution across critical aerospace and medical frontiers. Together, this dual-film synergy will drive China’s self-reliance and controllability in advanced materials.