TE Raychem DR-25 Heat Shrink Tubing Selection Guide
TE Raychem DR-25 Heat Shrink Tubing Selection Guide
TE Connectivity Raychem DR-25 is a fluid-resistant, flame-retardant heat shrink tubing family designed to protect electrical wiring and cable harnesses in demanding environments. Manufactured from a crosslinked elastomer, DR-25 provides abrasion resistance, flexibility and protection against selected automotive, aviation and industrial fluids.
With a 2:1 shrink ratio and an operating temperature range of -75°C to +150°C, DR-25 is widely considered for motorsport wiring harnesses, automotive electrical systems, aerospace wiring and industrial cable protection.
This guide explains DR-25 specifications, the differences between standard DR-25 and DR-25-TW thin-wall tubing, how to select the correct diameter, installation considerations and purchasing requirements.
1. What Is TE Raychem DR-25 Heat Shrink Tubing?
DR-25 belongs to the RAYCHEM heat shrink tubing portfolio from TE Connectivity. It is designed for applications where cables require mechanical protection and resistance to exposure from selected fuels, oils and other operating fluids.
When heat is applied, the tubing shrinks around a cable or wire bundle, providing a close-fitting protective sleeve.
Key Features
Fluid resistance: Designed for exposure to selected fuels, oils, hydraulic fluids and other specified liquids.
Temperature rating: -75°C to +150°C operating range.
2:1 shrink ratio: Suitable for a range of cable and harness diameters.
Crosslinked elastomer construction.
Flexible, abrasion-resistant protection.
Flame-retardant material.
Standard-wall and thin-wall product variants.
DR-25 is a single-wall tubing product. It should not automatically be considered a waterproof, adhesive-lined sealing system. Where environmental sealing is required, additional qualified sealing components may be necessary.
2. TE Raychem DR-25 Technical Specifications
The following specifications summarize representative DR-25 family characteristics from TE Connectivity product documentation.
| Parameter | Specification |
|---|---|
| Manufacturer | TE Connectivity |
| Brand | RAYCHEM |
| Product Series | DR-25 / DR-25-TW |
| Product Type | Heat Shrink Tubing |
| Material | Crosslinked Elastomer |
| Shrink Ratio | 2:1 |
| Operating Temperature | -75°C to +150°C |
| Primary Color | Black |
| Construction | Single Wall |
| Flammability | Flame-Retardant |
| Fluid Resistance | Aviation Fuel, Diesel, Hydraulic Fluid, Lubricating Oil and Other Specified Fluids |
| Main Applications | Wire Harness Protection, Abrasion Resistance, Strain Relief |
| Recovery Temperature | Check Exact Size and Variant; 175°C Is Listed for Representative TE Products |
| Available Versions | Standard DR-25 and DR-25-TW Thin Wall |
Important: Operating temperature is not the same as the installation recovery temperature. Always follow the manufacturer's heating recommendations for the exact part number.
3. DR-25 vs DR-25-TW: What Is the Difference?
One of the most common questions is whether standard DR-25 and DR-25-TW can be used interchangeably.
Both belong to the same fluid-resistant elastomer tubing family, but their wall constructions differ.
| Feature | DR-25 | DR-25-TW |
|---|---|---|
| Type | Standard-Wall Tubing | Thin-Wall Tubing |
| Material | Crosslinked Elastomer | Crosslinked Elastomer |
| Shrink Ratio | 2:1 | 2:1 |
| Operating Temperature | -75°C to +150°C | -75°C to +150°C |
| Wall Thickness | Thicker for Corresponding Sizes | Reduced Wall Thickness |
| Flexibility | Flexible | Very Flexible |
| Fluid Resistance | Yes, per Specification | Yes, per Specification |
| Typical Selection Priority | Protection and Mechanical Robustness | Reduced Bulk and Flexible Harness Construction |
| Relevant TE Specification | RK-6008/X1 | RK-6008/X2 |
When Should You Choose Standard DR-25?
Standard DR-25 may be preferred when the application requires the thicker wall dimensions defined by the selected product specification.
It is appropriate for evaluation in cable protection applications where mechanical robustness, abrasion resistance and fluid resistance are important.
When Should You Choose DR-25-TW?
DR-25-TW may be preferred when harness flexibility, weight and reduced sleeve bulk are important design requirements.
However, a thinner wall should not be assumed to provide the same level of mechanical protection as a thicker-wall version under every condition.
Replacement note: Compare the exact expanded diameter, recovered diameter, recovered wall thickness and applicable material specification before substituting DR-25-TW for standard DR-25.
4. How to Select the Correct DR-25 Tubing Size
Correct diameter selection is critical to achieving a secure fit and avoiding excessive stretching or insufficient recovery.
Two dimensions must be considered:
Expanded inside diameter: The minimum internal diameter before shrinking.
Recovered inside diameter: The maximum internal diameter after unrestricted full recovery.
For a typical 2:1 tubing size, the nominal expanded diameter is approximately twice the recovered diameter.
Step 1: Measure the Largest Installation Diameter
Measure the maximum outside diameter the tubing must pass over, including connectors, splices, terminals or harness transitions.
The tubing's specified minimum expanded inside diameter must be large enough to pass over this feature.
Step 2: Measure the Final Covered Diameter
Measure the wire or cable bundle diameter at the intended final position.
Choose tubing with a maximum recovered inside diameter smaller than the covered diameter so it can shrink into contact with the assembly.
Step 3: Allow Installation Margin
Do not select tubing with an expanded diameter exactly equal to the maximum installation feature.
Allow sufficient clearance for assembly tolerances, tubing ovality, harness irregularities and installation handling.
Step 4: Check Wall Thickness and Flexibility
After determining the correct diameter, compare standard and thin-wall variants based on the required mechanical protection and bending characteristics.
5. Example: DR-25-TW-3/16-0-SP
A representative TE Raychem part number is DR-25-TW-3/16-0-SP, corresponding to TE internal product number 4816334002.
This model belongs to the thin-wall DR-25 family and is supplied as black, single-wall, crosslinked elastomer heat shrink tubing.
| Parameter | DR-25-TW-3/16-0-SP |
|---|---|
| Manufacturer | TE Connectivity / RAYCHEM |
| Part Number | DR-25-TW-3/16-0-SP |
| TE Internal Number | 4816334002 |
| Product Type | Thin-Wall Heat Shrink Tubing |
| Expanded Inside Diameter (Minimum) | 4.8mm (0.189in) |
| Recovered Inside Diameter (Maximum) | 2.4mm (0.094in) |
| Recovered Wall Thickness (Nominal) | 0.51mm (0.020in) |
| Shrink Ratio | 2:1 |
| Operating Temperature | -75°C to +150°C |
| Recovery Temperature | 175°C |
| Color | Black |
| Material | Crosslinked Elastomer |
| Packaging | Spool |
Source: TE Connectivity official product record for DR-25-TW-3/16-0-SP.
Example Size Calculation
Suppose a cable bundle has a final outside diameter of 3.5mm and the largest feature that the tubing must pass over measures 4.0mm.
For DR-25-TW-3/16-0-SP:
Minimum expanded diameter: 4.8mm
Maximum recovered diameter: 2.4mm
Final cable diameter: 3.5mm
Largest installation feature: 4.0mm
The initial dimensional check indicates that the tubing may fit over the 4.0mm feature and can recover onto the 3.5mm cable.
However, this example does not establish a guaranteed installation fit. Confirm assembly clearances, actual recovered wall dimensions and applicable manufacturer installation requirements.
6. Common DR-25 Tubing Sizes
The following examples illustrate several DR-25-TW nominal sizes from TE Connectivity product listings.
| Part Number | Expanded ID (Min) | Recovered ID (Max) |
|---|---|---|
| DR-25-TW-3/16-0-SP | 4.8mm | 2.4mm |
| DR-25-TW-1/4-0-SP | 6.4mm | 3.2mm |
| DR-25-TW-1/2-0-SP | 12.7mm | 6.4mm |
| DR-25-TW-3/4-0-SP | 19.0mm | 9.5mm |
These are representative thin-wall product sizes, not a complete DR-25 size chart.
Wall thickness and other specifications may differ between sizes. Always check the selected part number's official product record.
7. How to Read a Raychem DR-25 Part Number
Consider the example:
DR-25-TW-3/16-0-SP
| Code | Meaning |
|---|---|
| DR-25 | Fluid-Resistant Elastomer Heat Shrink Tubing Family |
| TW | Thin-Wall Version |
| 3/16 | Nominal Expanded Tubing Size in Inches |
| 0 | Black Color Code |
| SP | Spool Packaging Designation |
When requesting a quotation, use the complete manufacturer part number, including wall type, nominal size, color and packaging designation.
Do not omit the TW suffix when the thin-wall version is specifically required.
8. DR-25 Fluid Resistance and Application Environments
A key advantage of DR-25 is its resistance to selected fluids encountered in demanding electrical harness environments.
TE Connectivity identifies resistance to several fluid categories, including:
Aviation fuel
Diesel fuel
Hydraulic fluid
Lubricating oil
Brake fluid
Water
Resistance is evaluated under defined manufacturer test conditions. The tubing should not be assumed compatible with every chemical formulation, temperature or exposure duration.
Motorsport Wiring Harnesses
Motorsport electrical systems often contain wiring routed near engines, hydraulic systems and mechanical components.
DR-25 is commonly considered for protective sleeving in such harnesses because of its heat resistance, fluid resistance and flexible construction.
Aerospace Wiring
Selected aerospace and aviation cable assemblies may require heat shrink tubing with controlled material properties and resistance to operating fluids.
Verify the exact applicable specification, certification and approved part number before using DR-25 in a regulated aerospace installation.
Industrial Cable Protection
Industrial equipment wiring can require mechanical protection against abrasion, vibration and incidental contact with oils or other process fluids.
DR-25 can be evaluated where its material properties meet the operating environment.
9. DR-25 Installation and Shrinking Guidelines
Correct installation is important for achieving a uniform protective sleeve.
Step 1: Prepare the Cable
Inspect the wiring assembly for sharp edges, damaged insulation or protruding components that could interfere with installation.
Step 2: Cut the Tubing
Cut the selected tubing to the required length, allowing for any longitudinal recovery specified by the manufacturer.
Step 3: Position the Tubing
Slide the tubing over the intended cable section and confirm that it covers the required area.
Step 4: Apply Controlled Heat
Use suitable hot-air equipment and follow the manufacturer's recommended installation temperature and heating procedure.
For representative DR-25-TW products, TE lists a recovery temperature of 175°C.
This is higher than the tubing's 150°C maximum continuous operating temperature. The two ratings describe different conditions.
Step 5: Inspect the Finished Assembly
After cooling, inspect for:
Uniform recovery around the cable bundle
Excessive wrinkles or incomplete shrinking
Overheating or surface damage
Damaged cable insulation
Sharp bends or unsupported strain points
Installation warning: Do not apply direct flame unless explicitly permitted by the approved installation procedure. Ensure that adjacent cable insulation, connectors and seals can withstand the required heating process.
10. DR-25 Replacement and Alternative Selection
When replacing DR-25 tubing, matching the nominal diameter alone is not sufficient.
Engineers and purchasing teams should compare:
| Parameter | Replacement Requirement |
|---|---|
| Material | Confirm elastomer chemistry and applicable material specification. |
| Shrink Ratio | Verify expanded and recovered diameter limits. |
| Wall Thickness | Compare recovered wall thickness and tolerance. |
| Temperature Rating | Check continuous operating and installation temperatures. |
| Fluid Resistance | Confirm compatibility with specific fuels, oils and chemicals. |
| Flame Resistance | Verify required flammability test results. |
| Flexibility | Evaluate bending requirements and harness movement. |
| Certification | Confirm applicable customer and industry approvals. |
| Packaging | Check cut lengths, spool format and order quantity. |
Important: Standard DR-25, DR-25-TW and other heat shrink tubing families should not automatically be described as direct replacements without verifying their material, mechanical and environmental performance.
11. Frequently Asked Questions
Q1: What is the operating temperature of Raychem DR-25?
Representative DR-25 and DR-25-TW products are rated for an operating temperature range of -75°C to +150°C. Confirm the exact product specification for the selected part number.
Q2: Is DR-25 resistant to fuel and oil?
Yes. TE Connectivity identifies resistance to selected aviation fuels, diesel, hydraulic fluids, lubricating oils and other specified fluids. Suitability depends on the actual chemical and exposure conditions.
Q3: What is the difference between DR-25 and DR-25-TW?
DR-25-TW is the thin-wall version. It offers reduced wall thickness and very flexible construction, while standard DR-25 uses a thicker wall for corresponding product sizes.
Q4: Is DR-25 heat shrink tubing waterproof?
DR-25 provides protective sleeving, but single-wall tubing alone should not be assumed to create a waterproof seal. For sealing applications, evaluate qualified adhesive-lined tubing, molded boots or compatible sealing systems.
12. Official TE Raychem DR-25 Datasheets
The following official TE Connectivity pages provide access to product drawings, specification sheets and selection documents.
Use the relevant product page to access the current TE drawing and the applicable RK-6008 material specification.
13. TE Raychem DR-25 Price, Availability & RFQ
Are you sourcing TE Raychem DR-25 heat shrink tubing for wire harness manufacturing, maintenance or production requirements?
DataStorageIC can assist with DR-25 and DR-25-TW sourcing inquiries, quotation requests and availability confirmation.
For an accurate quotation, please provide:
Manufacturer: TE Connectivity / RAYCHEM
Complete manufacturer part number
Required diameter and wall version
Required quantity or total length
Spool or cut-length packaging requirement
Target price, if available
Required delivery date
Destination country or region
Required material certificates or documentation
For replacement inquiries, include the original manufacturer part number and the required operating environment.
Request DR-25 Pricing and Availability: Contact DataStorageIC with your part-number requirements and required quantities.
Price, available inventory and delivery time are subject to confirmation.
14. Related TE Raychem Products
For additional heat shrink tubing and cable protection products, explore the following DataStorageIC resources:
TE / Raychem Heat Shrink Tubing and Cable Protection Products – Browse tubing, SolderSleeve and related cable protection products.
DataStorageIC Electronic Components – Submit BOM sourcing and component quotation inquiries.
Conclusion
TE Raychem DR-25 is a fluid-resistant, flame-retardant heat shrink tubing family designed for cable protection in demanding operating environments.
With its 2:1 shrink ratio, crosslinked elastomer material and -75°C to +150°C operating temperature range, DR-25 is a candidate for motorsport, industrial and selected aerospace wiring applications.
When selecting a specific model, engineers should compare expanded and recovered diameters, wall thickness, required heating conditions, fluid compatibility and relevant material specifications.
For DR-25 or DR-25-TW datasheets, pricing and availability inquiries, contact DataStorageIC with your required part number, tubing dimensions and purchase quantity.
