120W to 400W Ultra Thin Flexible Heaters Manufacturer

What is an ultra thin flexible heater?

An ultra thin flexible heater is a compact heating device built to deliver even warmth while adapting to different shapes and surfaces. They are made from thin substrates such as polyimide (Kapton) or silicone, combined with etched foil circuits or fine resistance wires.

The thickness can be as low as 0.13 mm. Even at this size, they can reach temperatures from -200°C up to 200°C. This ability to generate reliable heat in such a slim form is their key strength.

Unlike rigid heaters, they tolerate bending, shock, and vibration without losing performance. Their thin, lightweight form also allows engineers to integrate them into designs that require space-saving solutions.

How do ultra thin flexible heaters work?

The principle behind flexible heaters is resistive heating. When electrical current flows through the etched foil or resistance wire, the natural resistance generates heat. This heat is evenly distributed across the thin substrate, providing uniform thermal coverage.

Key design elements include:

• Heating Element: Etched copper-nickel foil or fine resistance wire.
• Insulating Substrate: Polyimide for thin, high-precision uses; silicone for rugged, moisture-resistant applications.
• Adhesive Backing: Often pressure-sensitive, allowing simple installation.
• Connectors & Leads: For easy integration with power supplies.

Response time is one of their strongest qualities. Many ultra thin flexible heaters reach working temperatures within 10 to 30 seconds, compared to several minutes for bulkier heating solutions. When paired with sensors or controllers, these heaters can maintain temperature stability within ±1°C, which is critical in medical and aerospace systems.

Benefits of ultra thin flexible heaters

• Lightweight and space-saving
• Fast heating response
• Uniform and stable heat
• Uniform heating
• Wide range of temperatures
• Withstand bending, vibration, and mechanical stress
• Shapes, voltages, and watt densities can be customized

Where are ultra thin flexible heaters commonly used?

• Medical Devices: Used in catheters, analyzers, and surgical equipment. Their slim form improves patient comfort and maintains precise temperatures.
• Aerospace and Avionics: Applied in cockpit displays, navigation systems, and sensors. They resist cold, shock, and vibration at high altitudes.
• Wearable Electronics and Smart Clothing: Integrated into smart textiles, gloves, and fitness devices. They deliver warmth without reducing comfort.
• Electric Vehicles and Drones: Battery heating pads improve energy performance in cold weather. Without heating, EV batteries can lose up to 20% efficiency in freezing conditions.
• Industrial and Optical Equipment: Prevent condensation in LCDs, cameras, and robotic systems. They also protect sensitive optical alignment tools.

What factors should be considered when selecting or designing one?

Several factors determine the success of a flexible heater design.

1. Material choice – Polyimide is thin and precise. Silicone offers more rugged protection.
2. Operating temperature – Match the heater to the device’s required temperature range.
3. Size and shape – CAD-based etching enables custom outlines for complex designs.
4. Power density – Choose watt density that provides effective heating without overheating.
5. Mounting method – Adhesive, clamps, or free-standing desgns can be used.
6. Sensor integration – Thermocouples, RTDs, or thermostats enhance precision and safety.

When these factors are addressed, heaters perform reliably and support long-term use.

Ultra-thin flexible heater case studies

1. 0.2mm Polyimide Heater for Medical Device

Product Name	Ultra thin Flexible Heater
Material	Polyimide (PI)
Total Thickness	0.2mm
Dimension	9.91mmx78.4mm±1mm
Power Density	3.0W/in2
Resistance	60Ohms±5%
Working Temperature	≤100℃
Back Adhesive	3M9460
Wire Type	Telfon AWG30
Wire Length	70mm±5mm
Soldering Area Thickness	≤2mm

2. 230W PI Heater for Industrial Usage

Product Name	Ultra thin Flexible Heater
Material	Polyimide (PI) + PCB
Conductor Thickness	50um
Dimension	160*209mm+40x25mm
Total Thickness	≤0.3mm
Current	14.6A
Power	230W
Resistance	1.1ohm
Environment Temperature	-40~150℃
Working Temperature	40℃
PCB Surface Treatment	ENIG 1U’’
Wire Length	16AWG 300mm

3. 12V Polyimide Heater for Consumer Electronics

Product Name	Ultra thin Flexible Heater
Material	Polyimide (PI) + PCB
Dimension	200*100mm
Total Thickness	0.2mm (PI heater + adhesive)
Voltage	12V (DC)
Power	40W
Environment Temperature	-10~15℃
Wire Length	235±5mm
Temperature Control	KSD9700 (-10℃~10±5℃)

Why Choose Danyu Electronics as Your Flexible Heater Supplier?

Danyu offers advanced thermal solutions with a strong focus on quality and customer needs. We are certified to ISO9001, ISO13485, IATF16949, and AS9100D, meeting the requirements of industries such as medical, automotive, and aerospace.

Our team provides:

• Expert design support.
• Fast prototyping within weeks.
• MES-based traceability during production.
• Stable pricing and reliable delivery.

By partnering with us, you gain heaters built for precision, durability, and safety. Whether you need standard or custom designs, we delivers solutions that keep your systems performing at their best.

Frequently Asked Questions

Q1: Are ultra thin flexible heaters safe to use?

Yes. With proper insulation and certification, they are safe for industrial and consumer use.

Q2: Can they be reused or repositioned?

Adhesive-backed types are usually for single use, while mechanically mounted heaters can be repositioned.

Q3: What is their typical lifespan?

With correct usage, they last five to ten years or longer.

Q4: Do they require external control?

Yes. Controllers or sensors maintain stability and improve energy efficiency.

Q5: Which certifications are important?

Look for ISO, CE, UL, and RoHS compliance, as well as sector-specific approvals.

Ultra thin flexible heaters provide a reliable way to manage heat in modern systems. Their slim profile, quick response, and precision control make them suitable for industries where size, weight, and accuracy are crucial.

From medical devices to EV batteries, they deliver dependable performance while adapting to unique requirements. As technology advances, their role will only expand. If you want high heating dissipation product, welcome to learn about our high-end product: Ceramic PCB and Metal Core PCB.

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