Heat Shrink Tubing Guide: Sizes, Ratios & Selection

What Is Heat Shrink Tubing?

Heat shrink tubing is a flexible plastic sleeve that shrinks in diameter when exposed to heat, forming a tight, protective covering over wires, cables, connectors, and other components. The tubing is supplied in its expanded state — sized to slide easily over the object being protected — and contracts to its recovered (shrunken) diameter when heat is applied, gripping the substrate firmly.

The underlying mechanism is straightforward: the tubing is manufactured from a thermoplastic polymer that has been cross-linked and then mechanically expanded while hot, locking in internal stress. When heat is reapplied, the cross-linked structure relaxes and the tubing returns toward its original, smaller diameter. This process is one-way — once the tubing has recovered, the shrinkage cannot be reversed.

Heat shrink tubing serves multiple functions simultaneously, which is why it is a standard consumable across so many trades and industries:

• Electrical insulation — covering bare conductors, splice joints, and terminations to prevent short circuits and current leakage
• Mechanical protection — shielding wire and cable from abrasion, vibration, and physical damage at gland entries, conduit ends, and cable tray edges
• Environmental sealing — creating a moisture, dust, and chemical barrier when dual wall adhesive-lined tubing is used
• Strain relief — reducing flexing stress at the point where a cable enters a connector, plug, or enclosure, which prevents conductor fatigue failure
• Cable identification — colour-coding conductors and bundles so circuits can be traced and maintained
• Bundling — grouping multiple cables into a single tidy run for easier routing and panel management
• Repair — restoring insulation integrity over minor cable damage, removing the need to replace the full cable

Heat shrink tubing is stocked by licensed electricians, auto electricians, marine electricians, electronics technicians, panel builders, and maintenance tradespeople across a wide range of industries — from light manufacturing and food processing to mining, construction, and marine. It is one of those consumables that does multiple jobs well, and the cost per joint is minimal relative to its value in protecting an installation.

In Australia, heatshrink (written as one word in trade catalogues and product listings) is available in a range of materials, shrink ratios, diameters, and colours, each suited to a specific set of applications and environmental conditions. Choosing the right product for the job is the topic of the rest of this guide.

Heat Shrink Tubing vs Shrink Wrap: Not the Same Product

A common source of confusion in search results and hardware stores: "shrink wrap" and "heat shrink tubing" both contract under heat, but they are completely different products manufactured from different materials for entirely different purposes.

Shrink wrap (also called stretch film, pallet wrap, or heat shrink film) is a polyethylene packaging material used to bundle and protect products during storage and shipping. It is applied as a film or bag over the product, then heated to shrink the film tight. Pallet wrap, food packaging film, and retail product wrapping are all forms of shrink wrap.

Heat shrink tubing is a hollow sleeving product used in electrical and cable management — it slides over wires, connectors, and cable assemblies before heating. The two products share the word "shrink" and both use heat, but the similarity ends there. This article covers electrical heat shrink tubing only. If you are looking for pallet or packaging film, that is a separate product category entirely.

Shrink Ratios Explained: 2:1, 3:1 and 4:1

The shrink ratio is one of the first specifications you will encounter when selecting heat shrink tubing. It describes how much the tubing contracts in diameter from its expanded (supplied) state to its fully recovered (shrunken) state. A 2:1 ratio means the tubing shrinks to half its original expanded diameter — a tube supplied at 20mm expanded inner diameter will recover to approximately 10mm. A 3:1 ratio means the tubing shrinks to one third of its original expanded diameter. A 4:1 ratio shrinks to one quarter.

The ratio does not describe length change. Heat shrink tubing does shorten slightly along its length as it recovers — typically 5-10% — but length change is minor and not the primary selection criterion.

2:1 Ratio — The Standard Choice

The 2:1 ratio is the most common and covers the majority of general electrical applications. It is the default choice when the cable or component being covered has a relatively uniform diameter and there is no significant step change to accommodate. 2:1 single wall tubing is available in the widest range of sizes, materials, and colours. Typical applications: insulating spliced conductors, protecting cable terminations, strain relief at gland entries, colour-coding in panel wiring, and bundling cable runs.

3:1 Ratio — For Step Changes and Sealed Applications

The 3:1 ratio is preferred in two situations: where the tubing needs to cover a step change in diameter, and where dual wall adhesive-lined construction is required. Most dual wall (adhesive lined) heat shrink is manufactured in 3:1 ratio because the higher recovery ensures the adhesive layer can fully contact and conform to the cable across a wider range of diameters.

A step change in diameter occurs, for example, when covering a connector body and its exit cable — the connector barrel may be 15mm across while the exit cable is 6mm. A 2:1 tube sized to slide over the connector would recover to 7.5mm, which may not grip the thinner cable firmly. A 3:1 tube sized the same way would recover to 5mm — gripping the cable securely while still fitting over the connector body. In automotive, marine, and caravan applications where moisture sealing is required, the standard recommendation is 3:1 dual wall adhesive.

4:1 and Higher — Specialist and Heavy Industrial

4:1 ratio tubing is used where very large diameter variations must be bridged, or where extremely tight recovery over complex shapes is needed. Common in mining cable repairs (large multi-core cables with significant connector steps), subsea applications, and heavy industrial electrical installation. Less common in general trade electrical work.

Quick Reference: Which Ratio to Choose

Single Wall vs Dual Wall (Adhesive Lined) Heat Shrink

The construction type — single wall or dual wall — is often more important than the ratio when it comes to whether a heat shrink application will perform correctly over its service life. Choosing single wall where dual wall is required is one of the most common errors, and it typically does not become apparent until months later when corrosion or moisture ingress causes a failure.

Single Wall Heat Shrink

Single wall heat shrink is a single layer of thermoplastic — typically cross-linked polyolefin. When heated, it shrinks and grips the cable firmly, providing electrical insulation, abrasion resistance, and mechanical protection. It does not seal against water, moisture, or fluid ingress. Where the cable surface and tubing are in contact, the grip is firm; but at the ends of the tubing, where it exits over the cable, there is no adhesive bond — moisture can wick in from the ends under the right conditions.

Single wall is the correct choice for: general cable insulation in indoor and protected environments; protecting terminations at terminal blocks, connectors, and DIN rail components in switchboards; colour-coding conductors at panel entries and distribution boards; bundling cable runs in cable trays and conduit systems; strain relief at cable gland entries in enclosures; and electronics assembly — covering solder joints on PCBs and connector pins.

Dual Wall (Adhesive Lined) Heat Shrink

Dual wall heat shrink has an inner layer of thermoplastic adhesive bonded to an outer layer of cross-linked polyolefin. When heat is applied, two things happen simultaneously: the outer polyolefin layer shrinks and the inner adhesive layer melts and flows, filling all the voids and gaps between the tubing and the cable surface. At the ends of the tube, the adhesive flows out slightly and creates a fillet seal — bonding the tubing to the cable insulation and preventing moisture from wicking in from either end.

The result is a fully waterproof, environmentally sealed joint that resists water immersion, salt spray, condensation, fuel and oil contamination, and vibration-induced joint loosening. Dual wall is not optional in any of the following situations:

• Marine wiring — any connection on a boat exposed to the elements, bilge area, deck, or below waterline penetrations
• Battery terminal connections — automotive, caravan, marine, and solar storage — the combination of high current, acid fumes, and moisture makes bare crimped connections degrade rapidly
• Outdoor and underground splices — direct-buried cable joins, irrigation system wiring, exterior lighting feeds
• Engine bay automotive wiring — heat, vibration, fuel, and water exposure in engine compartments
• Under-vehicle wiring — trailer connections, underbody chassis wiring, towing plugs exposed to road spray
• Caravan and motorhome electrical — 12V DC systems at solar connections, Anderson plugs, water pump wiring, and any external run
• Industrial wash-down environments — food processing, beverage processing, and any facility where high-pressure water or cleaning chemicals contact wiring
• Mining — cable repairs in wet underground environments, high-humidity cable runs

The Hansa HSA88 dual wall adhesive kit (88 pieces covering the most common diameters from 3mm to 25mm) is an efficient solution for auto electricians, marine electricians, and caravan service technicians who need a full range of adhesive-lined sizes on hand without stocking individual sizes separately.

How to Identify Which You Have

If you are unsure whether a tube is single or dual wall, cut a short length and look at the cross-section. Single wall shows a uniform layer of the same material throughout. Dual wall shows an outer layer (typically black or coloured polyolefin) and an inner layer of a lighter-coloured adhesive that will feel slightly tacky at room temperature. When you apply heat to a cut piece of dual wall, the adhesive layer will bubble and flow — this confirms the inner layer is functioning correctly.

Heat Shrink Tubing Materials: Polyolefin, PVC, PTFE and More

The material determines operating temperature range, chemical resistance, flame performance, flexibility, and environmental durability. For the overwhelming majority of Australian trade and industrial applications, the choice is between cross-linked polyolefin and PVC. The specialty materials are worth knowing but rarely needed in general trade work.

Cross-Linked Polyolefin — The Standard

Cross-linked polyolefin (XLPO) is the material used in quality industrial, electrical, and automotive heat shrink tubing. Its properties make it the correct default choice for virtually all trade applications:

• Flame retardant — self-extinguishing when the ignition source is removed. Does not propagate flame along a cable run.
• Non-toxic when burned — does not emit hydrogen chloride (HCl) gas, unlike PVC. Critical in enclosed spaces and public buildings where cable fires can affect evacuation.
• UV resistant — does not degrade or become brittle when exposed to Australian sunlight in outdoor installations.
• Wide temperature range — rated for continuous service from -55°C to +135°C, with short-term exposure to +150°C. Suitable for engine bay applications, outdoor installations in northern Australia, and cold-store environments.
• Chemically resistant — resists fuels, oils, common solvents, and many industrial cleaning agents.
• Flexible — maintains flexibility at low temperatures, unlike PVC which becomes stiff and brittle below -20°C.

Champion DRS single wall and Champion DWRS dual wall adhesive tubing are both cross-linked polyolefin. This is the material you should default to for any industrial, automotive, marine, or outdoor application.

PVC — Budget Option with Limitations

PVC heat shrink is cheaper than polyolefin and still used in entry-level and budget products. It is acceptable for indoor, non-critical cable management in environments that are dry, protected from UV, and not subject to flame exposure or extreme temperature. Its limitations in the context of Australian trade work:

• Operating temperature range typically -20°C to +105°C — inadequate for engine bay or high-ambient applications
• Emits hydrogen chloride (HCl) — a toxic, corrosive gas — when burned. PVC is restricted or banned in many public, rail, and mining applications in Australia.
• Degrades under UV exposure — becomes brittle and cracks in outdoor applications within 12-18 months
• Becomes stiff and difficult to work with at low temperatures

For the modest price premium, polyolefin is the better investment in any application where reliability matters.

PTFE — High-Temperature and Chemical Specialist

PTFE (polytetrafluoroethylene) is used in aerospace, laboratory, and extreme industrial applications. Properties: chemically inert to almost all solvents, rated from -200°C to +260°C continuous service, very low friction coefficient. PTFE heat shrink requires a higher shrink temperature (typically 327°C) than a standard heat gun can reliably achieve. It is a specialist specification product — not a general trade item.

Silicone and Fluoroelastomer

Silicone heat shrink offers excellent flexibility across a very wide temperature range and good UV resistance. Used in some high-temperature automotive applications and military electronics. Fluoroelastomer (Viton) is used in aggressive chemical environments — concentrated acids, fuels, and hydraulic fluids. Both are specialist products for defined applications, not general-purpose industrial consumables.

Material Comparison

A note on Raychem: TE Connectivity's Raychem brand is effectively the generic term for premium industrial heat shrink tubing in Australian trade usage — in the same way that "Biro" became generic for ballpoint pen. When an electrician specifies "Raychem tubing," they mean a fully data-sheet-compliant, premium-grade cross-linked polyolefin product. It is a quality benchmark, not the only supplier of quality tubing in the Australian market.

How to Choose the Right Size Heat Shrink Tubing

Sizing heat shrink tubing correctly is where most beginners go wrong, and the mistake is almost always the same: measuring the cable diameter and selecting tubing that matches it exactly. If you do this, the tubing will not slide onto the cable before heating. The correct process is two steps: measure the object, then select tubing with an expanded (pre-shrink) inner diameter that is comfortably larger — and a recovered (post-shrink) inner diameter that is smaller than the object OD, so it grips after heating.

Step 1: Measure the Cable or Component Outer Diameter

Use a digital vernier caliper. Measure at the widest point. For a cable bundle, measure the finished bundle at its widest diameter. For a connector with an exit cable, measure the connector body — the tubing needs to slide over the largest part of the assembly before the joint is made. If you do not have a caliper, a tape measure will give a close enough reading for most applications. The critical thing is to measure the right dimension — the outer diameter of the object at its widest point, not the conductor cross-section area.

Step 2: Select the Right Tubing

Select tubing where the expanded inner diameter (listed on the packaging as the "before" size) is at least 20-30% larger than the measured OD of your cable — so it slides on easily — and the recovered inner diameter (listed as the "after" size) is smaller than the measured OD — so it grips firmly after heating. This means you are always looking at both numbers on the product specification, not just one.

Practical Sizing Reference

Conductor Size vs Cable OD — An Important Distinction

Conductor size (in mm²) is not the same as cable OD. A 2.5mm² conductor in a single-core cable has an OD of approximately 3-4mm depending on insulation thickness and manufacturer. A multi-core 2.5mm² cable may have an OD of 7-9mm. Always measure the actual cable OD — do not try to infer it from the conductor cross-section area.

For 3:1 dual wall tubing, you can select a smaller expanded ID for the same cable OD — the higher recovery ratio means the tubing can start further from the cable surface and still grip firmly after recovery.

Heat Shrink Tubing Colours and Marking

Heat shrink tubing is manufactured in a standard range of colours, and colour selection has practical significance in electrical and industrial installations. Colour-coding enables circuit identification, maintenance tracing, and compliance with Australian wiring standards.

Standard Electrical Colour Coding (AS/NZS 3000)

AS/NZS 3000 (Wiring Rules) specifies conductor identification by colour for Australian electrical installations. Heat shrink tubing is used to mark repaired or re-terminated conductors where the original insulation colour has been removed, or to identify conductors at multi-core cable terminations:

When repairing or splicing a conductor, apply heat shrink tubing in the correct colour to restore the conductor's identification. A repaired active conductor that exits the heat shrink in the wrong colour creates a safety risk and a compliance issue under AS/NZS 3000.

In 12V DC systems — automotive, caravan, marine — the common convention is red for positive, black for negative or earth return, yellow for switched live (ignition-switched positive), and specific colours for trailer wiring functions (green for right turn, brown for left turn, purple for reverse). When repairing wiring in these systems, matching the original colour coding is important for ongoing fault-finding.

Clear Heat Shrink Tubing

Clear heat shrink is used where the connection or conductor detail needs to remain visible after installation — over soldered splices on PCBs where joint quality needs to be visible for inspection, over pre-printed cable labels to provide a durable waterproof sleeve, and in electronics work where component markings should remain readable. Clear tubing is also useful for verifying that the heat shrink has recovered fully and the joint looks correct before the installation is closed up.

Brady PermaSleeve Heat Shrink Labels

Brady PermaSleeve combines the cable identifier and the protective sleeve in one product. The label is pre-printed or field-printable using Brady label printers, then slid over the cable at the identification point and shrunk in place. The result is a permanent, readable, abrasion-resistant, and moisture-resistant cable label that cannot fall off, fade, or be accidentally removed. PermaSleeve is standard in industrial switchboard construction, cable tray installations, and any professional electrical installation that requires long-term cable identification under AS/NZS 3000 or site-specific labelling requirements.

How to Apply Heat Shrink Tubing: Tools and Technique

Correct application makes the difference between a joint that lasts the life of the installation and one that starts failing within months. The process is simple, but the order of steps and tool selection matter.

Tools Required

Heat gun — the correct tool for heat shrink application. A standard heat gun adjustable between 90°C and 200°C covers all standard heat shrink materials. For occasional use, a hardware-store hot air stripper (designed for paint stripping) produces sufficient heat at the right temperature. For trade use, a dedicated heat gun with temperature control and a concentrator nozzle is worth the investment — the nozzle focuses airflow into the tubing, producing faster, more even recovery.

Scissors or cable insulation stripper — for cutting tubing to length. Standard scissors work for most sizes. For small-diameter tubing (under 4mm), a sharp hobby knife or flush-cut snips give a cleaner edge. Avoid diagonal cuts — a square cut ensures even overlap at the ends of the joint.

Digital caliper — for confirming cable OD before selecting tubing, and for measuring cut lengths to ensure consistent overlap.

Step-by-Step Application

1. Cut the tubing to length before starting the joint. The tubing needs to extend past the joint on both sides — at least 10-15mm of overlap onto undamaged insulation on each side of the splice. Cut 5-10% longer than your final target to allow for slight lengthwise shortening during recovery.
2. Thread the tubing onto the wire before making the joint. This is the step most beginners miss on the first attempt. Once a crimp is made or a solder joint is completed, you cannot slide the tubing over it — it must be on the wire first. Slide the cut piece well back from the work area so heat from soldering or crimping does not accidentally activate it early.
3. Make the joint — solder the splice, crimp the connector, or terminate the conductor as required. Allow any solder joint to cool fully before proceeding — applying heat shrink over a still-hot joint can cause the adhesive layer to activate unevenly.
4. Slide the tubing into position — centred over the joint, with equal overlap onto cable insulation on each side. Adjust the position now — once recovery starts, repositioning is not possible.
5. Apply heat from one end, working toward the other. Start at one end of the tubing and move steadily toward the other, keeping the airflow moving at a pace that allows complete recovery without dwelling. For short pieces, start at the centre and work outward to both ends simultaneously — this prevents air pockets from being trapped at one end.
6. Keep the gun moving. Holding the heat gun in one spot causes localised overheating — the tubing surface will char, blister, or develop stress whitening. The heat gun nozzle should be moving continuously during recovery.
7. Check the result before the joint cools. A correctly recovered piece should be uniformly tight, conforming closely to the cable shape, with no lifted sections, bubbles, or white stress marks. For dual wall adhesive-lined tubing, the adhesive should be visible beading slightly at both ends — this confirms the inner layer has fully activated and the seal is complete.

Heat Gun vs Lighter vs Torch

The heat gun is the correct tool. Open-flame sources — lighters, matches, and candles — concentrate heat in a small point, cause uneven shrinkage, char the tubing surface, and risk burning the cable insulation underneath. A small butane torch is better than a lighter if a heat gun is not available — kept moving and held at 80-100mm from the tubing surface, it produces more even heat distribution. But it still requires more care than a heat gun and produces more char on the tubing surface. For volume work — an auto electrician making up a wiring loom, a marine electrician wiring a boat — a heat gun with a focused nozzle pays for itself rapidly in time saved and quality improvement.

Common Application Mistakes

• Forgetting to thread the tubing before making the joint — the single most common mistake. There is no fix except cutting the joint apart and starting again.
• Using tubing that is too small — if it does not slide on easily, it is the wrong size. Forcing it risks tearing or kinking the tubing.
• Dwelling the heat gun in one spot — always keep the gun moving.
• Applying heat shrink over a warm solder joint — let the joint cool first.
• Not allowing enough overlap — at least 10-15mm past the joint on each side. Shorter overlaps create a mechanical weak point.
• Using single wall in a moisture environment — if the installation is exposed to water, condensation, or wash-down, single wall is not sufficient. Use dual wall adhesive-lined.

Static Cling — Practical Tip for Small Tubing

Heat shrink tubing smaller than 4mm in diameter clings aggressively to itself, to bench surfaces, and to gloves due to static electricity. Working on an anti-static mat significantly reduces the problem. Alternatively, lightly wiping the tubing with a cotton cloth before cutting discharges the static and makes the pieces much easier to handle — particularly useful when cutting multiple small pieces for electronics assembly work.

Heat Shrink Tubing by Application: Electrical, Automotive, Marine and Industrial

The correct product choice varies significantly by industry and application. The following covers the most common use cases in Australian trade work.

General Electrical — Licensed Electricians and Electrical Contractors

In general electrical work, single wall 2:1 cross-linked polyolefin is the standard. Key applications include repairing minor cable insulation damage (significant insulation failures require full cable replacement per AS/NZS 3000 and must be assessed by a licensed electrician); protecting conductor terminations at terminal blocks, multi-way connectors, and junction boxes; providing strain relief at cable gland entries to enclosures and switchboards; and colour-coding conductors at switchboard entries and distribution boards.

In switchboard construction, heat shrink is applied at the termination point of each conductor to restore insulation, identify the conductor, and prevent bare conductor exposure near adjacent terminations. Panel builders typically stock 4mm, 6mm, 12mm, and 20mm expanded diameter in brown, blue, yellow/green, and black to cover standard conductor sizes and colour coding requirements under AS/NZS 3000. AIMS Industrial supplies a broad range of electrical and electronic products suited to panel building and site electrical work.

Automotive — Auto Electricians and Vehicle Accessories

Automotive electrical work uses both single wall (for loom protection in dry interior locations) and dual wall adhesive-lined (for any connection exposed to under-bonnet conditions, water, or vibration). Key applications:

• Battery terminal protection — dual wall adhesive over the battery post connection and cable lug. Acid fumes, condensation, and vibration will destroy an unprotected connection over time.
• Towing plug repairs — 7-pin trailer connectors are exposed to road spray, mud, and weather. Dual wall over each conductor termination inside the plug housing is standard practice.
• Aftermarket accessory wiring — driving lights, dual battery systems, solar regulators, and inverters. Use single wall for connections inside the cabin; dual wall for anything in the engine bay, under the vehicle, or exposed to weather.
• Wire loom repair — repairing damaged loom where insulation has been chafed by a sharp edge or heat source. Re-route the cable if possible; if not, repair with correctly sized single wall and add a protective layer of split conduit or loom tape over the repair area.

Marine and Boating

Marine electrical work is where the difference between single wall and dual wall adhesive heat shrink has the most significant consequences. Saltwater is highly corrosive, condensation is constant in bilge and cockpit areas, and vibration from engines and hull flex puts mechanical stress on every connection. The standard for quality marine wiring in Australia is tinned copper wire (not plain copper) as the conductor base material, dual wall adhesive-lined heat shrink at every termination and splice, and marine-rated tinned crimp terminations. For heat shrink tubing, cable ties, split conduit, and other wire and cable management products, AIMS Industrial stocks the full range for marine and industrial use.

The adhesive seal in dual wall tubing prevents the moisture ingress that causes the corrosion that eventually fails the connection. Single wall heat shrink in a marine environment provides temporary protection at best — condensation wicks into the ends of the tube and the connection corrodes from the inside, invisible until the system fails. For bilge pump wiring, running light connections, navigation electronics, VHF radio, and any deck or mast wiring — dual wall adhesive only.

Caravan and Motorhome

Caravan 12V DC electrical systems combine vibration (road travel), moisture (under-floor and external runs), and the consequences of failure at inconvenient times and locations. Any connection that is under the vehicle, external, or in an area exposed to road spray requires dual wall adhesive-lined heat shrink. Interior wiring in a dry location can use single wall, but connections at Anderson plugs, solar regulators, battery terminals, external LED strips, and towing connections should always be dual wall.

Industrial and Mining

Wash-down environments (food processing, beverage, meat works) require dual wall adhesive with appropriate material rating for the cleaning chemicals used. Standard polyolefin resists most industrial cleaning agents — check the data sheet for compatibility with specific chemicals. Cable identification in control rooms and panel buildings uses heat shrink labels or colour-coded sleeving. High-temperature applications above +135°C require silicone or PTFE construction. Chemical plant applications require material selection based on the specific chemicals present — consult the product data sheet before specifying.

Heat Shrink Connectors and Terminals

Heat shrink connectors are a time-saving solution that integrates the mechanical electrical connection and the heat shrink moisture seal in a single product. They are widely used in automotive, marine, caravan, and industrial wiring where both a reliable crimp connection and an environmentally sealed joint are required at the same location.

Construction and Operation

A heat shrink connector consists of a standard crimp barrel (butt splice, ring terminal, spade terminal, bullet connector, or other type) with an adhesive-lined heat shrink sleeve pre-moulded over the barrel. To use: strip the wire, insert into the connector barrel, and crimp as normal using the correct crimp tool for the connector gauge. Then apply heat with a heat gun — the sleeve recovers over the conductor, and the inner adhesive flows and creates a waterproof seal around the conductor entry point. The complete process — from stripped wire to sealed, terminated connection — takes only slightly longer than a standard crimp alone, and the result is far more reliable in exposed environments than a crimp followed by separately applied heat shrink.

Colour Coding and Wire Gauge Range

Heat shrink connectors follow the same colour-coded wire gauge convention used in standard crimp terminals:

Always match the connector colour to the wire gauge. An undersized connector will not grip the conductor properly; an oversized connector will allow the conductor to move in the barrel, leading to resistance, heat generation, and eventual connection failure.

Types of Heat Shrink Connectors

• Butt splice connectors — join two conductors end to end. Available in straight (in-line) and step-down versions for joining two different gauge wires.
• Ring terminals — crimp termination with a ring eyelet for bolted connections to battery posts, earth studs, and bus bars.
• Spade terminals — for push-on connector blocks and automotive harness connectors.
• Bullet connectors — inline connectors used in 12V DC wiring for joinable and breakable connections in caravan, boat, and automotive harnesses.

Heat shrink connectors are the more efficient choice for high-volume wiring work and for any connection in a moisture-critical environment. Separate crimp-then-shrink is preferred when you need a specific connector type not available in heat shrink form, when working with very large conductors (above 6mm²), or when you need to inspect the crimp quality before sealing it. AIMS Industrial stocks heat shrink tubing and a range of crimp terminals and connectors to suit both approaches.

Heat Shrink Tape vs Heat Shrink Tubing: What Is the Difference?

These two products serve a related purpose but work differently, and each has situations where it is the better choice. Heat shrink tubing is a hollow sleeve that must be slid over the cable before the joint is made. It shrinks uniformly under heat, providing consistent wall thickness and a clean, professional finish. It is stronger and more abrasion-resistant than tape-based alternatives and produces the best result when access to both ends of the cable is available.

Self-amalgamating tape (sometimes mistakenly called "heat shrink tape") is a silicone or butyl rubber tape that fuses to itself under pressure, without heat. You stretch and wrap it around the cable or connection, and the tape bonds to itself to create a waterproof, insulating layer. It requires no heat, no pre-positioning, and can be applied in situ on a connected cable — you do not need to disconnect the cable to apply it. Self-amalgamating tape is the better choice when: both ends of the cable cannot be accessed to thread tubing through before making the joint; the repair is done in situ without disconnecting the cable; the cable profile is too irregular for tubing to conform to; or a rapid field repair is needed without a heat gun.

Heat shrink tubing produces a better result when access permits. Self-amalgamating tape is the backup when access does not permit. True heat shrink tape (a tape-form version of heat shrink material for wrapping very large-diameter cables) does exist as a specialist industrial product, but it is not a general trade item in the Australian market — when "heat shrink tape" is mentioned in most trade contexts, self-amalgamating tape is what is meant.

Where to Buy Heat Shrink Tubing in Australia

AIMS Industrial stocks heat shrink tubing across the full range for industrial, electrical, automotive, and marine applications. Products are available online at aimsindustrial.com.au with delivery across Australia.

Champion DRS single wall heat shrink tubing — cross-linked polyolefin, 2:1 shrink ratio, multiple sizes and colours, rated -55°C to +135°C. The standard choice for general electrical, panel building, and industrial cable management. Supplied in 1m lengths.

Champion DWRS dual wall adhesive heat shrink tubing — cross-linked polyolefin outer, thermoplastic adhesive inner, 3:1 shrink ratio. Fully waterproof seal when correctly applied. The correct product for automotive battery terminals, marine wiring, towing connections, outdoor splices, and any moisture-critical application. Supplied in 1m lengths.

Hansa HSA88 dual wall adhesive heat shrink kit — 88-piece assortment of dual wall adhesive-lined tubing across the most common sizes from 3mm to 25mm expanded diameter. An all-in-one solution for auto electricians, marine electricians, and caravan service technicians who need a full range available without ordering individual sizes. The kit eliminates the problem of running out of a specific size mid-job.

Brady PermaSleeve heat shrink labels — heat shrink polyolefin cable identification labels for switchboard wiring, cable tray labelling, and permanent industrial cable identification. Compatible with Brady label printers. The professional solution for AS/NZS 3000 compliant cable identification in electrical installations.

Browse the complete heat shrink tubing range at AIMS Industrial, or explore the broader wire and cable management collection. If you need assistance selecting the right product for your application, contact the AIMS team.

For workshop and inspection measuring tools, see AIMS Measuring Tools.