Swaged single-end elements for moulds, hot runners, water tanks and machinery. At 30–50 W/cm² the fit between heater and hole decides life — so we machine to your bore tolerance, not to a catalogue size.
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Ranges we hold every day. Anything outside them is possible — it just needs a conversation before the drawing.
| Diameter | Ø3 / 4 / 6 / 8 / 10 / 12.5 / 16 / 20 / 25 mm (tolerance -0.02 / -0.08 mm) |
|---|---|
| Length | 20 – 1000 mm; 10 mm minimum unheated section at lead end |
| Watt density | Standard 10–25 W/cm² · High 30–40 W/cm² · Max 50 W/cm² with matched bore |
| Sheath material | SS304, SS316L, Incoloy 800 / 840, titanium (plating lines) |
| Voltage / power | 12–480 V · 50 W – 5 kW |
| Thread | M14×1.5, M18×1.5, 1/2" BSP, 3/4" BSP, 1/2" NPT, 1" NPT, custom |
| Terminals | Screw post, 2-pin ceramic plug, PTFE / fibreglass lead, high-temp 250 °C lead, armour braid |
| Sensor | Type J or K thermocouple built in, or RTD Pt100 pocket |
| Insulation resistance | ≥ 100 MΩ at 500 V DC · Dielectric 1500 V AC / 1 s |
| Fits | Bore tolerance H7 recommended; clearance 0.05–0.10 mm at high watt density |
| Max sheath temp | 750 °C (Incoloy), 600 °C (SS316L), 450 °C (SS304) |
Four things we control in the process, and four reasons elements fail in the field.
NiCr coil, resistance matched to ±3 %
Coil centred, MgO pre-filled
Rolled to final Ø, density ≥ 3.3 g/cm³
Thread, hex, flange face, TC hole
100 % hipot, IR, R, dimensional report
200 pcs repeat size · 500 pcs new tooling · samples from 1 pc
After drawing confirmation, including test data
Engineering-backed quote with the wall thickness and watt density stated
Up to 50 W/cm² on Ø10 mm and above with a matched bore and good heat sinking. Above 40 W/cm² we will ask for the block material and bore tolerance before accepting the order.
Yes — Type J or K built into the same sheath, or a separate Pt100 pocket. Internal TC responds 3–5× faster than a surface sensor.
Yes. Ø1/4", 3/8", 1/2", 5/8" and 1" bodies with NPT threads are standard for us, not specials.
100 pieces for cartridge heaters, 100 for screw-in types. Sample orders of 5–20 pieces are accepted at sample pricing.
Individually sleeved, leads protected, boxed with the test sheet per batch number. Mixed resistance sets are labelled so 3-phase groups stay matched.
Send a drawing, a sample photo or just the application — we will tell you what watt density and sheath you need before quoting.