Polyimide (Kapton®) heater

Kapton Heaters

Polyimide (Kapton®) is an organic polymer with very high dielectric capability and thin profile, while providing superior resistance to most solvents, oils, and radiation. In connection with these features, kapton heater is very ideal for applications with space and weight limitation, or where the heater will be exposed to chemical or oil. With low out gassing, these thermofoil heaters can also be used in vacuum environments. Special cord and plug sets available.

Being transparent, Kapton® film also allows easy visual inspection on the internal structures. Pressure-sensitive adhesive (PSA) backing surface is standard, but special adhesives or mounting holes can be customized per customer requirement.

Specification of Polyimide (kapton) Heater

  • Working voltage: 0 - 400V
  • Working temperature: -200°C - 200°C
  • Watt density: <7.8w/cm2
  • Mounting: PSA or mechanical
  • Max size: 500x600mm
  • Bending radius: >0.8mm
  • Exit: teflon, kapton or silicone insulated leads

Application of kapton heaters

  • Medical diagnostic instruments: Heat sample trays, reagent bottles, etc.
  • Stabilize optoelectronic components
  • Test or simulate integrated circuits
  • Enable cold weather operation of outdoor electronics such as laptap, ATM, LCD’s
  • Protect aircraft electronic and mechanical devices in cold weather / area


The Answer To Hundreds of Unique Heating Applications…


Designed for Trouble-Free Performance and Improved Operation Efficiency

Fullchance’s Flexible Heaters are capable of operating with excellent performance under many adverse conditions, including: moisture, outdoor exposure or ambient temperatures, radiation, ozone, compression set, vacuum, fungus, oils, solvents, and many other chemicals.

Flexible Silicone Rubber and Kapton Heaters also have very good mechanical properties. They are of low mass construction and provide rapid heat-up due to direct bonding to the part. Flexible Heaters are not affected by mechanical shock, vibration or repeated flexing and will not stretch or tear over a temperature range of -392°F to +500°F (-236°C to +260°C).




Select a Flexible Heater for your specific application...

Fullchance Flexible Heaters are a reliable and economical heat source capable of providing uniform heat transfer to irregular shaped or flat surfaces including three dimensional geometries, conforming to the part being heated.

Flexible heater use typically falls into the following applications:

  • Process Heat
  • Freeze Protection
  • Condensation Protection
  • Composite Bonding

Fullchance’s engineering staff, with many years of experience in heat processing and temperature control, can assist you in designing the right Silicone Rubber Flexible Heater for your application.

Fullchance's Flexible Heaters offer unlimited design possibilities!


Standard Flexible Specifications

Kapton® Heater Specifications

Physical Size and Construction Limitations
Maximum Size:
Dimensional Tolerance:
Less than 6":
6" to 12":
Over 12":

Nominal Thickness:


Performance Ratings

Maximum Operating Temperature:
Minimum Operating Temperature:

Physically Resistant To:

Electrical Ratings


Maximum Operating Voltage:

Dielectric Strength:

Standard Leads:

10" × 22" (25.4 × 56.9 cm)

±0.030" (0.76 mm)
±0.060" (1.52 mm)
±0.125" (3.17 mm)

0.006" (0.15 mm)

1.5 oz./ft2 (0.05g/cm2)

392°F / 200°C Continuous

-320°F / -195°C

Moisture, Ozone, Fungus

Foil: +10%, -10%

480 Vac

1000 Vac

10" Teflon® Insulated
Stranded Wire

Note: Other materials are available such as neoprene rubber, SIlicone or vinyl plastic. Consult Fullchance for more information.

Flexible Heater Wattage Recommendations

Step 1   Determine the Required Wattage
Every process has a unique wattage requirement to heat that particular load up to temperature or to maintain a particular temperature.

If the required heater wattage is not known, estimate the required wattage using the thermodynamic formulas listed in chapter 16, Engineering. A safety factor of 25% additional wattage is recommended to compensate for unknown variables.

To raise the temperature of an aluminum plate 6" × 12" × 0.5" (3.53 lb.) 200°F (from 70° to 270°F) in 0.5 hours:

Add safety margin 108 W + 25% = 135 watts

Step 2 Determine the Heater Size and Watt Density
A flexible heater should use the maximum space available for mounting and heating the process. Factors that affect heater size include the mounting method and watt density.

Suggested Maximum Watt Density by Mounting Method - Degrees Fahrenheit
Suggested Maximum Watt Density by Mounting Method - Degrees Centigrade

Kapton Standard (Non-Stock) Sizes and Ratings

Squares and Rectangles

How To Order
Catalog Heaters

Chose from the tables of common sizes of Kapton in round or rectangular shapes.
The heaters listed are 5 W/in2. Standard configuration includes 10" Teflon® leads, exit style A or L (see page 9-7) and no mounting option.

Custom Engineered/Manufactured Heaters

Understanding that an electric heater can be very application specific, for sizes and ratings not listed, Fullchance will design and manufacture a Flexible Surface Heater to meet your requirements.
Standard Lead time is 7 to 9 days

Please Specify the following:

  • Diameter
  • Wattage and Voltage
  • Lead Type
  • Sensors or Thermostats
  • Special Features or Cutouts
  • Lead Location



Flexible heaters furnish fast warm-up, precise heat, and long life in virtually any shape, size, and wattage.
Flexible Kapton heaters provide highly efficient heat transfer over a wide temperature range. The thin, lightweight, and flexible design provides superior surface conformance.. extending heater life by minimizing the thermal gradient between resistive element and heat sink. In addition, flexible heaters feature low outgassing, tear resistance, and dimensional stability.

Limitless Designs
Flexible heaters are available with integral RTD's, thermocouples, or thermistors for optimum response time and gradient control. Sensors can be laminated inside a heater, adhered to the heater surface, or installed at specific locations within the system to prevent overshoot and heat fluctuations.

Factory Bonding
Proper heat-to-part installation is critical to achieving a tight bond, superior performance, and high reliability. For optimum heater performance and cost effectiveness, we can factory mount a heater to your thermal subassembly. You can supply the heat sinks or have us fabricate them to your specification, giving you a guaranteed bond, superior reliability, and the benefit of our extensive experience in bonding techniques.

Contact us today for an innovative and custom solution for your heater needs. We also offer a variety of standard sized heaters with different resistence values allowing you to test your prototypes.

Flexible Heater-1

Flexible Heater-2

Flexible Heater-3

Flexible Heater-4

Flexible Heater-5

Flexible Heater-6

Flexible Heater-7

Flexible Heater-8


Flex circuits can be shaped to fit where no other design can. They are a hybrid of ordinary printed circuit boards and round wire, exhibiting benefits of each. In essence, flex circuits give you unlimited freedom of packaging geometry while retaining the precision density and repeatability of printed circuits.
Fullchance specializes in tight tolerance, fine-line flex circuits, with different types of flex circuits offer different advantages.  Some offer lower cost, others increased functionality.  We’ll work with you to ensure a circuit solution tightly aligned with your requirements.

High Density Interconnect (HDI)
Increased design, layout and construction options over typical flexible circuits



Blend of rigid and flex emphasizing the best of both constructions



Exceptional performance and reliability in situations where the circuit is exposed to excessive vibration or shock combined with frequent bending or folding



  Double Sided
Access circuit traces from both the top and bottom sides of the circuit, for greater flexibility in design and functionality



Single Sided
Unmatched flexing ability and ease of design, especially in applications that demand repetitive movement



  Flex Coils
Combine antenna coils and flexible or rigid-flex circuits in one rugged package



Value-Added Options
Complete flex circuit solutions that make interconnection efficient and affordable, and provide turnkey assemblies