Ultra-thin mirror aluminium is bright-rolled, high-purity aluminium in gauges from about 0.08 mm, finished by anodising or vacuum coating to give total light reflectance from around 86 % up to 95 %. At 0.08 mm it uses about 84 % less metal than a 0.5 mm mirror sheet, which makes it attractive for reflector liners, laminates and decorative films. This guide explains grades, finishes, measurement and where thin gauges work best.
Mirror aluminium is sheet or coil whose surface has been rolled on polished work rolls to an extremely smooth, bright finish and then protected or enhanced so that it reflects light specularly, like a mirror. "Ultra-thin" refers to gauges well below the 0.3 – 1.0 mm normally used for luminaire reflectors, down to about 0.08 mm.
At 0.08 mm the material is, strictly, in foil territory: EN 546 treats aluminium thinner than 0.2 mm as foil, and ASTM uses a limit of about 0.15 mm. In practice it is still sold as "mirror sheet" because it is made by the same bright-rolling and finishing routes and is used for the same optical purposes, either self-supporting in small parts or laminated to a carrier.
The economic case is simple. Aluminium weighs 2.70 kg per square metre per millimetre, so a 0.08 mm sheet weighs 0.216 kg/m² against 1.35 kg/m² for 0.5 mm. Thin gauges cost more per kilogram to roll and finish, but far less metal is needed per square metre of reflective surface, so for laminated or lined products the cost per square metre is often much lower.
| Type | How it is produced | Typical total reflectance | Notes |
|---|---|---|---|
| Bright-rolled, coated | Mirror rolling of 1xxx alloy, then a clear lacquer or protective film | About 80 – 86 % | Economical; used for decoration, signage and general reflectors |
| Anodised mirror | High-purity (e.g. 99.85 %) bright-rolled coil, chemically or electrolytically brightened, then thinly anodised | About 85 – 88 % | Hard, durable oxide layer; the standard luminaire reflector material |
| PVD-enhanced aluminium | Anodised substrate plus a vacuum-deposited pure aluminium layer and dielectric reflection-enhancing layers | About 95 % | Highest reflectance of all-aluminium systems; used in high-efficiency lighting and daylight systems |
| Silver-based PVD | Silver reflective layer under protective layers on an aluminium carrier | About 98 % | Shown for comparison; the reflective layer is not aluminium |
Reflectance figures depend on the measurement standard. European suppliers usually quote total reflectance to DIN 5036-3 with an integrating sphere, while some data sheets use ASTM E1651. Diffuse (scattered) reflectance is quoted separately: a true mirror has low diffuse reflectance, while satin and "hammertone" grades scatter more light on purpose. Always compare grades measured to the same method.
Polishing, electropolishing and chemical brightening improve smoothness and brightness; anodising and lacquer protect the surface. Coloured mirror finishes (gold, champagne, rose gold and similar) are produced by coloured lacquers or coatings over the bright aluminium.
| Alloy | Purity / type | Mirror performance | Typical use |
|---|---|---|---|
| 1050 / 1060 | 99.5 – 99.6 % Al | Good brightness; usually lacquered or film-protected | Decorative, signage, general reflectors |
| 1070 | 99.7 % Al | Brighter after anodising than 1050 | Reflectors, lighting |
| 1085 / 1090 | 99.85 – 99.9 % Al | Highest specular brightness after brightening and anodising | High-efficiency luminaire and optical reflectors |
| 5005 | Al-0.8 % Mg | Anodising-quality grade, stronger than 1xxx | Architectural trims and stiffer reflectors |
| 3003 / 3105 | Al-Mn | Stronger, but manganese particles reduce anodised brightness; normally lacquer-coated | Decorative panels, automotive trim |
| 5052 | Al-2.5 % Mg | Good corrosion resistance; used where strength is needed more than peak reflectance | Facades, housings |
The rule of thumb: the purer the aluminium, the brighter the anodised mirror, because alloying elements and intermetallic particles show up as haze in the oxide layer. Claims of 94 – 95 % reflectance from ordinary alloyed sheet without a PVD layer should be questioned and checked against a measured data sheet.
| Thickness (mm) | Weight (kg/m²) | 1220 × 2440 mm sheet (kg) |
|---|---|---|
| 0.08 | 0.216 | 0.64 |
| 0.1 | 0.270 | 0.80 |
| 0.15 | 0.405 | 1.21 |
| 0.2 | 0.540 | 1.61 |
| 0.3 | 0.810 | 2.41 |
| 0.4 | 1.080 | 3.21 |
| 0.5 | 1.350 | 4.02 |
| 0.8 | 2.160 | 6.43 |
| 1 | 2.700 | 8.04 |
Example: covering 3,000 m² needs about 650 kg of 0.08 mm mirror aluminium against about 4,050 kg at 0.5 mm. Whether that reduces total project cost depends on the price per kilogram of each gauge and on the carrier or structure the thin sheet needs, so compare quotes per square metre, not per kilogram.
Yes, slowly. Dust, fingerprints, humidity and pollutants reduce it, and unprotected aluminium forms a thicker oxide over time. Anodised and PVD grades with a sealed top layer keep reflectance far better than bare or lightly lacquered material.
Use soft cloths with mild, neutral detergent and clean water. Abrasives, alkaline cleaners and solvents can damage anodised or lacquered layers.
Anodised reflectors tolerate the operating temperatures of most luminaires, but lacquered and coloured coatings have lower limits. Check the coating's rated temperature for lamps or solar receivers.
For outdoor or solar concentrator use, choose a grade with a weather-resistant protective layer tested for UV and humidity; standard indoor reflector grades can degrade outdoors.
Salt-spray and humidity test results should be part of the data sheet when the sheet will be used near the coast or in humid interiors.
Thin gauges dent and crease easily; keep the protective film on until after forming and installation.
At 0.08 – 0.2 mm, mirror aluminium can be slit, guillotined, die-cut and laser-cut, but its edges are sharp and the surface marks easily. Leave the protective film on during all cutting and forming, and use clean, polished tooling to avoid pick-up marks. For bends, the anodic layer of anodised grades can craze if the radius is too tight; follow the supplier's minimum bend radius for the specific grade and temper.
Lamination is the most common route for the thinnest gauges. Thin mirror aluminium is bonded to plastic sheet, honeycomb or foam panels, board or composite panels with pressure-sensitive or heat-activated adhesives. The bond side should be primed or treated for adhesion, and the laminate built so it does not curl when the temperature changes.
For thicker reflector sheet and optical grades, see the high-reflectivity aluminium sheet guide.
The most common mistakes we see are buying on a headline reflectance number without knowing the test method, using an indoor reflector grade outdoors, and ordering a gauge that is too thin for a self-supporting part. Another is removing the protective film before forming, which almost always leaves handling marks on the mirror face. Agree the finish, film type, coil inside diameter and packing (sealed, desiccated cases for sea freight) at the quotation stage so the material arrives ready for your line.
Mirror-finished aluminium is available from about 0.08 mm. At that gauge it is usually laminated or used as a liner, because it cannot support itself over large spans.
Lacquered bright-rolled sheet reaches roughly 80 – 86 %, anodised high-purity mirror about 85 – 88 %, and PVD-enhanced aluminium about 95 % total reflectance, measured to DIN 5036-3.
Standard mirror aluminium is bright-rolled and protected for appearance and moderate reflection. High-reflectivity grades use high-purity substrates, brightening and anodising, often with PVD reflection-enhancing layers, to reach 90 – 95 % for optical and lighting uses.
It declines slowly with dirt, humidity and surface oxidation. Sealed anodised or PVD protective layers and regular gentle cleaning keep the loss small.
Per square metre it often is, because far less metal is needed. Per kilogram it costs more, so compare quotes per square metre including any carrier or lamination.
Yes, within the minimum bend radius for the grade and temper. Tight bends can craze the anodic layer, so keep the protective film on and use softer tempers for deep forming.
Send gauge, width, finish and reflectance target. Our team will recommend a grade, arrange samples and quote delivery worldwide.
