Polyimide / Kapton^® Flexible Heaters

Epec’s Polyimide Flexible Heaters are your solution to heating curved and irregular surfaces. Due to their design, polyimide heaters can be extremely thin, as low as 0.007”, excluding any type of affixing adhesives. The etched circuit is pressed between 2-layers of polyimide film with either an FEP adhesive or an acrylic adhesive depending on the thermal characteristics required of the heater.

The design of a polyimide heater offers dimensional stability, superior tensile strength, and overall improved resilience. Polyimide is also resistant to most chemicals. Explore our blog post for more details, Polyimide Flexible Heaters: Durable High-Temperature Performance.

We offer multiple heating elements for polyimide heaters, such as stainless steel 304, CuNi44, and Inconel600, with excellent dielectric properties and operating environments between -319°F (-195°C) and 392°F (200°C). Kapton heaters also offer a quicker thermal transfer than silicone rubber heaters.

At a Glance: Polyimide / Kapton^® Flexible Heaters

• Polyimide/Kapton^® flexible heaters provide thin, durable heating solutions for curved and irregular surfaces, with operating temperatures ranging from -319°F (-195°C) to 392°F (200°C).
• The polyimide construction delivers excellent dielectric properties, dimensional stability, uniform thermal distribution, low outgassing, and watt densities up to 50 W/in².
• Custom design options include multizone heating, integrated sensors and controls, mounting features, internal cutouts, and precision-etched circuits manufactured to tight tolerances.

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Benefits of Polyimide/Kapton^® Flexible Heaters

Polyimide/Kapton^® heaters offer several benefits for customers looking to utilize them in many different applications. Below are some benefits of using Polyimide/Kapton flex heaters in your application.

• Heaters have a lower temperature threshold than silicone rubber heaters, as they can operate within temperatures as low as -320°F and as high as 400°F.
• Polyimide has superior dielectric properties as they exhibit excellent tensile strength, durability, and dimensional stability which makes it almost impossible to tear even using the thinnest dielectrics.
• These heaters produce uniform thermal distribution which prevents uneven material expansions even with rapid heat-up and cool-down characteristics.
• Watt densities up to 50 W/in² (7.75 W/cm²).
• Kapton^® heaters can provide thermal stability over a wide temperature range and quicker response on thermal delivery to the surrounding mass.
• The resistive property is inherent to the film, so it cannot be cracked, rubbed off or otherwise easily damaged.

Heaters made on Polyimide/Kapton^® material have low outgassing properties which means that the release of gas that was dissolved and trapped in the creating of the material is minimal. Outgassing can be a big problem if it collects in a closed environment where air moves slowly so the lower the emissions the better. Outgassed products can condense onto lenses and other sensors which is a problem if it collects in a closed environment.

Head over to our blog post, How Hot can a Flexible Polyimide Heater Get?

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Custom Polyimide/Kapton^® Flex Heater Solutions

Based upon the material to be heated (steel, aluminum, water, oil, plastic, air, etc.) custom designed and manufactured polyimide flexible heaters offer a low profile and rugged design while maintaining safety by being both abrasion and acid-resistant. Because we can create designs with any outline shape required, they are more cost effective and energy efficient than competitive solutions.

We utilize thermal imaging modeling based on your specs, that allow for design optimization as the image of the heater can be very precise as the photoimaging and chemical etching process can operate well within +/-0.003” tolerances. We have built our business on working with customers to design the perfect flexible heater for every application and are flexible enough to manage small quantities up to production volumes.

Features of a Custom Polyimide/Kapton^® Flexible Heater Design:

• Internal Cutouts
• +/-0.005” Using Mechanical Equipment
• +/-0.002” Using Laser Cutter
• Integrated Thermostats, Thermistors, Fuses and Other Components
• Mounting to Aluminum or Steel Supports
• Full Range of PSA’s (Pressure Sensitive Adhesives) To Meet Any Application
• Stiffeners for Connector Support
• Mounting Holes
• Multizone Heaters
• Various Wire Lengths, Sizes and Connector Options
• Pre-Formed Flexible Heaters
• Strain Reliefs at Connection Point to Ensure Reliability

Epec Engineered Technologies only designs and manufactures custom Kapton^®/polyimide flexible heaters but you can visit one of our partners Omega Engineering who offers a vast number of standard heater sizes that are in stock for instant delivery.

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Current Specifications for Polyimide Heaters

• Maximum Watt Density: 50 W/in²
• Maximum Operating Temperature: 392°F (200°C)
• Minimum Operating Temperature: -319°F (-195°C)
• Wattage Tolerance: ±10%
• Dielectric Strength: 1000 VAC

Here are a few temperature and power limits for polyimide flexible heaters.

Industry Benefits

Examples of industries that can benefit from the heating capabilities of a custom designed flexible polyimide heater include medical, aerospace, military, foodservice, and many more. Anywhere that operates with tight spaces and demanding conditions should consider the benefits of a Kapton heater.

See our blog post on the importance of flexible heaters in the medical industry for more information.

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Frequently Asked Questions

Quick Links

• What are the advantages of Polyimide/Kapton^® flexible heaters?
• What temperature range can Polyimide/Kapton^® heaters operate within?
• What customization options are available for Polyimide/Kapton^® flexible heaters?
• Why are low outgassing properties important in flexible heater applications?
• Which industries commonly use Polyimide/Kapton^® flexible heaters?

What are the advantages of Polyimide/Kapton^® flexible heaters?

Polyimide/Kapton^® flexible heaters are extremely thin, with designs as thin as 0.007" excluding mounting adhesives. The material provides excellent tensile strength, dimensional stability, durability, and resistance to many chemicals. These heaters also offer uniform thermal distribution and rapid thermal response. Their low-profile construction makes them particularly well suited for applications involving curved, irregular, or space-constrained surfaces.

What temperature range can Polyimide/Kapton^® heaters operate within?

According to the source, Polyimide/Kapton^® heaters can operate between -319°F (-195°C) and 392°F (200°C). The material can withstand both cryogenic and elevated-temperature environments while maintaining thermal stability. Polyimide heaters also offer a lower temperature threshold than silicone rubber heaters. This wide operating range makes them suitable for demanding industrial, aerospace, medical, and laboratory applications.

What customization options are available for Polyimide/Kapton^® flexible heaters?

Custom designs can include internal cutouts, mounting holes, multizone heating, strain reliefs, stiffeners for connector support, and a wide range of wire and connector configurations. Integrated thermostats, thermistors, fuses, and other control components can also be incorporated into the heater design. The source notes that heaters can be mounted to aluminum or steel supports and paired with various pressure sensitive adhesives. Custom outline shapes can be manufactured to meet specific application requirements.

Why are low outgassing properties important in flexible heater applications?

Low outgassing means that minimal amounts of trapped gases are released from the heater materials during operation. This characteristic is especially important in enclosed environments where air circulation is limited. According to the source, released gases can condense on sensitive surfaces such as lenses and sensors, potentially affecting system performance. Polyimide/Kapton^® heaters are designed with low outgassing properties to help reduce these concerns.

Which industries commonly use Polyimide/Kapton^® flexible heaters?

Polyimide/Kapton^® flexible heaters are used in industries that require reliable thermal management in demanding environments or confined spaces. The source identifies medical, aerospace, military, and foodservice applications as examples. Their combination of durability, thermal performance, chemical resistance, and design flexibility makes them suitable for a broad range of specialized equipment. Applications that require precise heating and limited installation space often benefit from this heater technology.

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Experience Superior Heating with Epec's Polyimide Flexible Heaters!

Our Polyimide/Kapton^® flexible heaters deliver unmatched durability, precise thermal distribution, and top-tier customization. Ideal for aerospace, medical, and more, they excel in the most challenging environments.

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