Standard Flexible Heaters Specifications & Thickness Chart

A flexible Kapton heater—also known as a polyimide flexible heaters—is an ultra-thin, lightweight flexible heating element that delivers reliable heat where traditional heaters cannot fit. Its unique construction, combining polyimide insulation with an etched metal foil, makes it suitable for aerospace, battery systems, medical devices, and precision instruments.

These heaters are valued for their flexibility, stability, and even heat distribution. Understanding their standard specifications and thickness chart is crucial for engineers when designing compact, high-performance thermal solutions.

What Are the Standard Specifications of a Flexible Kapton Heater?

A flexible Kapton heater uses polyimide film as both the base and cover layer, providing excellent electrical insulation, high temperature resistance, and chemical stability. Below are the general technical specifications for reference.

Parameter	Typical Specification	Description
Base Material	Polyimide (Kapton) Film	Lightweight and thermally stable
Heating Element	Etched Foil (NiCr / CuNi)	Uniform resistance and heat distribution
Operating Temperature	-200°C to +200°C (short term up to 260°C)	Wide thermal range for industrial use
Power Density	0.1 – 1.5 W/cm²	Customizable according to design
Voltage Range	5V – 240V AC/DC	Depends on the circuit design
Thickness Range	0.13 – 0.5 mm	Extremely thin and flexible
Dielectric Strength	>5000V	Strong insulation performance
Surface Insulation Resistance	≥100 MΩ at 500V DC	Stable and safe in humid environments
Mounting Option	PSA adhesive, mechanical fix, or silicone bonding	Versatile installation methods

These heaters can be fabricated in nearly any shape, including circles, rectangles, or complex contours, to suit different assembly requirements.

Standard Thickness Chart for Polyimide Flexible Heaters

Flexible heater thickness determines flexibility, response speed, and heat transfer efficiency. Below is a detailed thickness chart showing the structure of a polyimide flexible heater.

Layer	Material Type	Standard Thickness (mm)	Typical Range (mm)	Function
Polyimide Base Film	Kapton PI	0.025	0.0125–0.05	Electrical insulation and mechanical support
Heating Element	NiCr or CuNi foil	0.025	0.012–0.05	Heat generation through resistance
Adhesive Layer	Silicone / Acrylic	0.03	0.02–0.05	Binds heater layers securely
Polyimide Top Film	Kapton PI	0.025	0.0125–0.05	Protective insulation layer
Optional Pressure-Sensitive Adhesive	3M high-temp PSA	0.05	Optional	Surface mounting aid
Total Thickness	—	≈0.13 mm	0.13–0.5 mm	Flexible, compact construction

Note: For ultra-thin designs, total thickness can be reduced to 0.1 mm without sacrificing mechanical integrity.

Kapton vs Silicone Flexible Heaters – What’s the Difference?

Both Kapton (polyimide) and silicone rubber heaters are flexible, but they serve different environments and performance goals. The following table highlights their key differences to help you choose appropriately.

Comparison Factor	Flexible Kapton Heater	Silicone Flexible Heater
Base Material	Polyimide Film	Silicone Rubber
Thickness	0.13–0.5 mm	0.8–3 mm
Temperature Range	-200°C to +200°C	-60°C to +200°C
Flexibility	Extremely thin and bendable	Moderate flexibility
Weight	Ultra-light	Heavier
Dielectric Strength	High (>5000V)	Medium
Moisture Resistance	Excellent	Excellent
Chemical Resistance	Outstanding	Good
Durability	Long life, stable in vacuum	Strong in moisture-rich environments
Cost Level	Slightly higher	Moderate
Best Applications	Aerospace, electronics, sensors	Automotive, dehumidifiers, pipes

If your design requires ultra-thin construction, precise temperature control, and high electrical insulation, a flexible Kapton heater is the optimal choice. For larger or outdoor equipment that demands high durability and moisture protection, silicone heaters perform better.

How to Select the Right Polyimide Flexible Heater?

Choosing the correct heater involves balancing thermal output, size constraints, and environmental conditions. Key considerations include:

• Wattage and Voltage: Match the heater’s input with your system’s capacity.
• Temperature Uniformity: Use etched foil elements for even heating.
• Attachment Method: Opt for pressure-sensitive adhesive for smooth surfaces or mechanical clamping for rough ones.
• Sensor Integration: Include thermocouples or PT100 sensors for accurate temperature control.
• Shape and Size: Custom-cut options allow integration into tight or curved areas.

Careful parameter matching prevents overheating, extends product lifespan, and enhances safety performance.

Common Applications of Flexible Heating Elements

Flexible heating elements like Kapton or polyimide heaters are used across industries due to their adaptability and stability. Typical applications include:

• Medical Instruments: Fluid warmers, diagnostic analyzers, or patient care devices.
• Aerospace Systems: Satellite battery heaters, sensors, and optical devices.
• Telecommunication Equipment: Outdoor enclosure and antenna de-icing.
• Electric Vehicles: Battery preheating and temperature maintenance.
• 3D Printers: Bed surface heating and component stabilization.
• Laboratory Equipment: Precision incubators or analyzers.

Can Flexible Kapton Heaters Be Custom-Designed?

Absolutely. A polyimide flexible heater can be tailored for nearly any device geometry, power density, or voltage level. Customization options include:

• Etched foil design for precise thermal zones.
• Multi-layer assembly with temperature sensors.
• Leadwire exits and connector configurations.
• Integration with PCBs or metal substrates for hybrid systems.

Partnering with an experienced manufacturer guarantees accurate tolerance control, consistent resistivity, and long-term reliability.

Why Choose Danyu Electronics for Flexible Kapton Heaters?

Danyu electronics offers professional manufacturing of flexible Kapton heaters and polyimide flexible heating elements, serving industries from medical to aerospace. With expert design capabilities, global certifications, and top-tier production control, our engineering team provides full design support—from resistance pattern layout to thermal simulation—ensuring each heater meets your exact performance criteria. Here’s why choose us:

1. Every request is handled promptly, with responses typically delivered within 24 hours.

2. Our sales and engineering teams are well-trained and experienced in the thermal management field.

3. We provide OEM service with complete customization options to meet your specific requirements.

4. Free samples are available for testing, and our design team can tailor size, shape, resistance pattern, and voltage exactly to your project’s needs.

5. Whether you need a few prototype pieces or a full-scale production batch, we support small MOQ orders as well as large-volume runs

6. We work closely with long-term logistics partners to guarantee fast, safe, and cost-effective delivery.

If you’re ready to discuss your heater requirements, feel free to reach out to our sales or engineering team.

Email us at sales@best-heaters.com in your convenient time, we’ll be happy to provide a prompt and detailed response.

tags：flexible heating element · flexible kapton heater · polyimide flexible heater