Polyimide Heaters Manufacturer

What is a Flexible Polyimide Heater?

Their flexibility allows them to wrap around pipes, tanks, and complex shapes. This unique feature provides targeted heating, improving energy efficiency and reducing heat loss. When combined with a polyimide flexible circuit, the heater can achieve intricate designs and fit into compact spaces.

Types of Flexible Polyimide Heaters

1. Standard Flexible Polyimide Heaters – These basic heaters provide uniform heat distribution over flat or slightly curved surfaces. They are commonly used in lab equipment and small electronics.
2. Kapton Polyimide Heaters – Named after the Kapton film they use, these heaters can withstand temperatures up to 400°C. They are ideal for aerospace and industrial applications where high heat resistance is essential.
3. Custom-Shaped Polyimide Heaters – Designed for irregular or curved surfaces, these heaters are cut to fit the exact shape required. Customization ensures optimal heating performance and avoids wasted energy.

Main Components of Polyimide Flexible Circuit

1. Polyimide Substrate – Provides the flexible base and insulation. Its thermal and chemical stability allows the circuit to endure extreme conditions.
2. Conductive Traces – Typically made from copper, these traces carry current through the heater. They can be patterned precisely to achieve uniform heating or specific heat zones.
3. Adhesive Layers – Bond the conductive traces to the polyimide substrate while maintaining flexibility and electrical insulation.
4. Protective Coating – Optional layers protect against moisture, abrasion, and chemical exposure, ensuring the heater performs reliably over its lifespan.
5. Terminal Connectors (Optional) – Allow easy electrical connections to the heater. These may be flat tabs, wire leads, or soldered pads, depending on the application.

These components work together to deliver controlled heat while maintaining flexibility and reliability in compact or irregular applications.

Polyimide Heaters vs Flexible PCB Heater

1. Polyimide Heaters – Focus primarily on delivering heat. While they may include simple electrical connections, their primary function is uniform heat output. They are thinner, more flexible, and often cheaper than flexible PCB heaters.

1. Flexible PCB Heater – Combines heating and circuit functionality. It can include sensors, controllers, and other electronic components embedded into the same flexible substrate. This allows for more complex applications but may slightly reduce flexibility due to additional components.

Choosing between the two depends on your needs. If heating is the primary goal, polyimide heaters are ideal. If your device requires integrated electronics with heating, a flexible PCB heater may be the better solution.

How are Polyimide Flexible Circuits Integrated in Heaters?

1. Circuit Design – Engineers design the trace pattern according to the desired heat distribution. Advanced software ensures each zone receives the correct current.
2. Substrate Preparation – Polyimide sheets are cleaned and prepared to accept conductive traces.
3. Trace Patterning – Copper traces are applied using photolithography or etching techniques. The trace layout directly affects the heater’s efficiency and heat uniformity.
4. Insulation and Protection – Adhesive layers or protective coatings are added to prevent electrical shorts and mechanical damage.
5. Terminal Attachment – Leads or connectors are attached for power input. Precision in this step ensures reliable operation and long-term durability.
6. Testing – Each heater is tested for resistance, heat uniformity, and mechanical flexibility. This ensures the final product meets exact performance requirements.

Through this process, polyimide flexible circuits become an integral part of the heater, providing controlled, efficient heating with the ability to conform to complex shapes.

Advantages of Flex Polyimide Heaters

1. Kapton and other polyimides can tolerate temperatures up to 400°C without degrading.
2. Can conform to pipes, cylinders, and complex shapes. This flexibility expands application possibilities.
3. Thin and light, these heaters are suitable for portable and miniaturized devices.
4. Precision trace patterns provide consistent heating over the entire surface.
5. Targeted heating reduces energy consumption, as heat is applied only where needed.
6. Resistant to chemicals, moisture, and mechanical stress, making them suitable for harsh environments.

These advantages make flex polyimide heaters indispensable in medical, aerospace, electronics, and industrial applications.

Our Polyimide Heater Manufacturing Capability

What Kind of Services We Provide

1. Our engineers work closely with clients to select the right heater type, optimize trace patterns, and choose appropriate substrates for each application.
2. We produce prototypes quickly to help clients validate designs, test performance, and refine their products before mass production.
3. Whether small batches or large-scale orders, we ensure consistent quality, precise trace layouts, and reliable heater performance.
4. We assist with integrating heaters into final devices, providing guidance on positioning, mounting, and electrical connections.
5. Resistance, insulation, and voltage tests guarantee safety and performance under operational conditions.
6. We provide support for maintaining and troubleshooting polyimide heaters, helping clients extend product life and avoid downtime.
7. Recommendations on substrate types, adhesive layers, and protective coatings to match environmental and thermal requirements.
8. Rapid turnaround services, expedited design, prototyping, or production for clients with tight project timelines.
9. Ongoing support for heater performance monitoring, replacement parts, and application improvements.

Certifications We Have

1. ISO9001 – Ensures consistent quality management and product reliability.
2. ISO13485 – Certification for medical device production, highlighting safety and regulatory compliance.
3. RoHS & REACH Compliance – Guarantees products are environmentally friendly and safe for global markets.

Advantages of Cooperated with Danyu Team
If you are looking for a reliable polyimide heater manufacturer, do not miss out Danyu. We have over 10 years experience in flexible circuit heater fabricating, we have strong R&D team that can provide with you the best solution and give you some professional suggestions that tailored to your design. If working with Danyu electronics, you can enjoy:

1. Fast prototype and delivery
2. COC report for each product
3. No MOQ requirements
4. Highest quality that compliant with ISO9001
5. 9 step quality inspection during manufacturing
6. 1 year quality assurance
7. Free DFM check
8. Installation guide for each order
9. Various material options like polyimide, PET, silicone rubber, transparent heater
10. Customized shapes, voltage, watts, dimensions

Whether you need a standard polyimide heater, a custom-shaped solution, or an integrated flexible PCB heater, Danyu electronics offers tailored manufacturing, strict quality assurance, and full-service support. With international certifications and advanced production capabilities, we are your reliable partner for high-performance heating solutions.

A silicone rubber heater is a flexible heating element made from silicone rubber sheets with embedded resistance wires. It provides efficient and uniform heat while remaining lightweight and durable.