Thick Film Heaters for Medical Instruments: Reliable Precision Heating

Thick film heaters play a vital role in
medical instruments, where precise temperature control is critical for reliable
performance. These advanced heaters, made by applying resistive and conductive
pastes onto ceramic, stainless steel, or other substrates, offer fast thermal
response, even heat distribution, and compact designs—perfect for medical
applications where space is limited and accuracy is essential.

Benefits for Medical Devices

• Space-saving design fits compact
  instruments.
• Highly customizable for unique device
  geometries.
• Fast thermal response enhances process
  efficiency.
• Long-term durability reduces downtime.
• Even heat distribution improves accuracy
  and safety

Examples of Medical Instruments Using
Thick Film Heaters

• Blood Analyzers & Diagnostic Devices –
  Precise sample heating for accurate analysis.
• Surgical Instruments & Endoscopes –
  Heating elements for temperature regulation during procedures.
• DNA Amplification Systems (PCR Machines) –
  Rapid thermal cycling for genetic testing.
• Patient Warming Devices – Even heat
  distribution for therapeutic purposes.
• Sterilization Systems – Reliable heating
  for disinfection processes.

Case Study of Thick Film Heaters in
Medical Device

Customer Background‌

‌Company‌: MedLife Innovations

Industry‌: Medical
Equipment Manufacturing

Application‌:
Precision temperature control in portable hemodialysis systems

‌Key Requirements‌:

l   Maintain ‌37±0.5°C‌ fluid temperature during dialysis, even in ambient
temperatures ranging from ‌5°C to 40°C‌.

l   Achieve ‌IP68 waterproofing‌ for sterilization compatibility (autoclave and chemical wash).

l   Minimize electromagnetic interference to avoid disrupting sensitive
biosensors.

‌Project Challenges‌ ‌

1. Existing heaters caused ‌±1.2°C fluctuations‌, risking patient discomfort and treatment efficacy. ‌

2.Traditional heaters degraded
after ‌50 autoclave cycles‌ (121°C,
2 bar pressure). 

3. Required heating elements to fit within ‌10mm × 40mm‌ flow channel geometry.

Danyu’s Solutions

According to the requirements, our team developed
ultra-thin (0.4mm) platinum-palladium heaters with EMI shielding, surviving 250
sterilization cycles and 10k bends. Achieved ±0.28°C accuracy, cut failure rates to 0.4%, and accelerated MedLife’s FDA approval by 4 months.

Results & Customer Satisfaction

‌Customer Feedback‌:

l   ‌Customer Feedback‌: ‌Satisfaction Score‌: 9.7/10 (post-clinical trial survey). ‌

l   Clinical Impact‌: Enabled MedLife’s hemodialysis system to achieve ‌EN
13532:2025‌ certification for home healthcare use. ‌

l   Market Success‌: Launched in Q3 2024, capturing ‌22%‌ of the EU portable dialysis market within 6 months.