Product Overview

When standard off-the-shelf heaters won't fit or perform, our Custom Cartridge Heaters provide the perfect solution. We specialize in manufacturing high-density tubular heating elements tailored to your exact specifications. Whether you need a unique geometry, exotic materials, or specialized termination, our engineering team works with you to design a heater that integrates seamlessly into your equipment.

From aerospace and semiconductor manufacturing to medical devices and plastic molding, our custom heaters deliver reliable, high-performance thermal energy in the most demanding environments.

Customization Capabilities

We offer a comprehensive range of customization options to meet your specific engineering requirements:
1. Geometry & Dimensions
Diameter: Any diameter from 2mm to 50mm.
Length: Custom lengths to fit your borehole depth perfectly.
Bending & Forming: We can bend heaters into U-shapes, L-shapes, or complex curves to fit around obstacles.
Swaging: Tapered ends for easy insertion and removal.
Flattened Sections: For surface contact heating applications.

2. Sheath Materials
Select the best material for your environment:
Stainless Steel (SS304/316): General purpose, corrosion-resistant.
Incoloy 800/840: High oxidation resistance, ideal for high-temperature air heating.
Inconel 600: Superior resistance to chloride-ion stress corrosion cracking.
Titanium: Excellent for heating corrosive liquids and acids.
Copper/Aluminum: For rapid heat transfer in lower temperature applications.

3. Termination & Wiring
We provide various exit configurations to simplify installation:
Straight Pins: Rigid pins for direct socket connection.
Flying Leads: Flexible high-temp wires (Fiberglass, Silicone, PTFE).
Terminal Boxes: IP-rated enclosures for harsh environments.
Grounding Options: Exposed ground braid or screw terminals.
Angled Exits: 90° or 45° wire exits to save space.

4. Integrated Sensors
Combine heating and sensing in one unit:
Built-in Thermocouples: Type J, K, or T.
RTDs: PT100 or PT1000 for high precision.
Dual Elements: Two independent heaters in one sheath for redundancy.

Technical Specifications

Parameter                           Customization Range
Voltage                               12V – 660V (AC/DC)
Wattage                             10W – 5000W+
Watt Density                   Up to 60 W/cm² (High Density)
Sheath Diameter          2mm – 50mm
Heated Length             10mm – 6000mm
Cold Section                Adjustable unheated length (5mm – 100mm+)
Insulation                     High-purity Compacted MgO

Applications

Our custom heaters are designed to solve specific thermal challenges in:
Semiconductor Manufacturing: Ultra-clean heating for wafer processing.
Medical Equipment: Precise, safe heating for diagnostic machines.
Plastic Extrusion: Specialized profiles for melt pumps and dies.
Aerospace: Lightweight, high-reliability heaters for extreme altitudes.
Battery Production: Heating rollers and presses for electrode manufacturing.
Food Processing: Sanitary designs for ovens and sealing bars.

Our Engineering Process

Consultation: You provide your application details, space constraints, and thermal goals.
Design: Our engineers create a CAD model and calculate the optimal watt density and cold section.
Prototyping: We manufacture a sample for your testing and validation.
Production: Once approved, we manufacture your custom heaters with strict quality control.

Quality Assurance

Every custom heater undergoes rigorous testing before shipment:
Hi-Pot Test: Verifies dielectric strength and insulation integrity.
Resistance Check: Ensures wattage tolerance is within ±5% or ±10%.
Visual Inspection: Confirms surface finish and dimensional accuracy.