The general manufacturing process for thermally conductive double-sided tape involves mixing thermally conductive fillers with an adhesive in a solvent, adding an initiator and a cross-linking agent, and then coating the mixture onto a release liner, fiberglass cloth, or other substrate to form the tape. Tapes produced via this process are characterized by low cost and excellent thermal conductivity.

For example, Patent CN120192717A discloses a method for preparing an electrically insulating, thermally conductive double-sided tape; the raw materials include butyl acrylate, ethyl acrylate, acrylic acid, modified aluminum nitride, a solvent, an initiator, and a cross-linking agent. The use of acrylates for the pressure-sensitive adhesive component imparts excellent initial tack and flexibility to the tape. The cross-linking agent contains multiple polymerizable double bonds, which serve to enhance the tape's peel strength. Meanwhile, the modified aluminum nitride significantly improves the tape's thermal conductivity, electrical insulation, and heat resistance.

Regarding application, pressure must be applied when using thermally conductive double-sided tape to optimize bonding performance. Specifically, it is recommended to maintain the assembly under a pressure of 10–30 psi at room temperature for a certain period to strengthen the bond. Before application, ensure that the bonding surfaces are free from oil, dust, or other contaminants that could compromise adhesion. While a significant portion of the bond strength is achieved quickly after application, full curing may take longer; typically, 70% of the ultimate bond strength is attained upon initial application, with the final strength reached within 36 hours.