Customized Kapton Heater Polyimide Thin Film Heating Pad

What Is a Kapton (Polyimide) Heater?

A Kapton heater, also known as a polyimide heater, is an ultra-thin flexible electric heater manufactured by laminating an etched foil heating element between layers of high-performance polyimide film.

Compared with silicone rubber heaters, polyimide heaters are significantly thinner, lighter, and offer faster thermal response, making them ideal for compact devices where installation space is limited.

These heaters are widely used in aerospace, medical equipment, laboratory instruments, battery packs, semiconductor manufacturing, optical systems, defense electronics, and precision industrial equipment.

Product Structure

 A typical polyimide heater consists of:

• Polyimide Film (Kapton®)

• Precision Etched Foil Heating Element

• High-Temperature Adhesive

• Electrical Insulation Layer

• Flexible Lead Wires

• Optional Temperature Sensor (PT100, Thermocouple, NTC)

• Optional PSA Adhesive Backing

Benefits of Etched Foil Technology

• Superior temperature uniformity

• Rapid heat transfer

• Low thermal mass

• Precise watt density

• Excellent repeatability

• Longer operating life

Key Features

Ultra-Thin Profile

Thickness can be as low as:

• 0.15 mm

• 0.20 mm

• 0.25 mm

Ideal for applications with extremely limited installation space.

Exceptional Temperature Uniformity

Precision etched foil technology distributes heat evenly across the entire surface, minimizing hot spots and ensuring accurate temperature control.

Lightweight Design

Compared with traditional heaters:

• Lower weight

• Smaller footprint

• Easier integration

• Improved system efficiency

Perfect for portable devices and aerospace equipment.

Excellent Chemical Resistance

Polyimide film resists:

• Oils

• Fuels

• Solvents

• Vacuum environments

• Radiation

• Moisture

• Aging

Fast Thermal Response

Because of its low thermal mass, the heater reaches operating temperature quickly and cools down rapidly, making it ideal for precision thermal control.

Technical Specifications

Optional Features

Customers can customize:

• Adhesive Backing (3M PSA)

• PT100 Sensor

• NTC Thermistor

• K-Type Thermocouple

• Thermal Fuse

• Thermostat

• Multiple Heating Zones

• Cut-outs

• Mounting Holes

• Connector Types

• Shielded Leads

Applications

Aerospace & Aviation

Used for:

• Aircraft Electronics

• Satellite Systems

• Avionics

• Radar Equipment

• Space Instruments

Advantages:

• Lightweight

• Reliable

• Low Outgassing

• Excellent Thermal Stability

Battery Heating

Ideal for:

• Lithium Batteries

• EV Battery Packs

• Energy Storage Systems

• Outdoor Battery Cabinets

Benefits:

• Improved low-temperature performance

• Stable charging

• Extended battery life

Medical Equipment

Common applications include:

• Diagnostic Devices

• Blood Analyzers

• DNA Instruments

• Incubators

• Medical Imaging Equipment

Semiconductor Manufacturing

Widely used for:

• Wafer Processing

• Vacuum Chambers

• Probe Stations

• Precision Temperature Control

• Chip Manufacturing Equipment

Optical & Laboratory Equipment

Suitable for:

• Laser Systems

• Optical Sensors

• Scientific Instruments

• Spectrometers

• Laboratory Automation

Electronics

Typical applications:

• LCD Modules

• Display Systems

• PCB Heating

• Embedded Electronics

• Industrial Automation

Kapton Heater vs Silicone Rubber Heater

Recommendation:

• Choose Polyimide heaters when space is limited, weight matters, or precise temperature control is required.

• Choose Silicone rubber heaters for larger surfaces, industrial tanks, or general-purpose heating.

Manufacturing Process

Our production process includes:

1. Precision foil etching

2. Polyimide film lamination

3. Vacuum bonding

4. Lead wire welding

5. Sensor integration

6. Electrical testing

7. Final inspection

8. Packaging

Quality Assurance

Every heater is 100% tested before shipment:

• Resistance Test

• Insulation Resistance Test

• Dielectric Strength Test

• Power Verification

• Dimension Inspection

• Appearance Inspection

Design Guide

To design the optimal polyimide heater, please provide:

• Heater dimensions (L × W)

• Supply voltage

• Required wattage

• Target temperature

• Heating surface material

• Operating environment

• Adhesive backing requirement

• Sensor type

• Lead wire direction

• Connector type

Our engineering team will recommend the most suitable solution.

Frequently Asked Questions

Is Kapton heater the same as Polyimide heater?

Yes. Kapton® is DuPont’s trademark for polyimide film. In industrial applications, the terms are often used interchangeably.

Can the heater operate in a vacuum?

Yes. Polyimide heaters are widely used in vacuum systems due to their low outgassing characteristics.

Can I order custom shapes?

Yes. We manufacture heaters in virtually any shape, including round, oval, ring, rectangular, and highly customized geometries.

What is the maximum operating temperature?

Typical continuous operating temperature is up to 200°C, with short-term exposure up to approximately 260°C, depending on the application.

Can temperature sensors be integrated?

Absolutely. PT100, NTC thermistors, K-type thermocouples, and other sensors can be embedded during manufacturing.

Why Choose HOTBOX?

• ✔ 20+ Years of Flexible Heater Manufacturing

• ✔ Precision Etched Foil Technology

• ✔ Custom Engineering Support

• ✔ ISO-Compliant Quality Control

• ✔ Rapid Prototype Development

• ✔ Competitive Factory Pricing

• ✔ Global Export Experience

• ✔ Fast Technical Response

Request a Custom Quote

Looking for a custom Kapton® or polyimide heater?

Our engineers can help you design a high-performance heating solution tailored to your application.

Contact us today with your drawings or specifications for a fast quotation.