Products

Custom Polyimide (Kapton®) Heaters

Symtec manufactures custom polyimide flexible heaters using Kapton® and other high-performance polyimide films. Our thin-film heater designs deliver precise, uniform heat in the most demanding environments — from aerospace avionics to electric vehicle battery systems. Every heater is engineered and manufactured in our USA facility to your exact specifications.

Why Choose Polyimide Heaters?

Polyimide flexible heaters are the preferred solution when thin profile, light weight, and high-temperature performance are critical. Built on polyimide film substrates as thin as 0.2mm, these heaters conform to complex surfaces and fit into tight assemblies where traditional heating elements cannot. With operating temperatures up to 200°C (392°F) and excellent chemical resistance, polyimide heaters excel in aerospace, defense, medical, semiconductor, and EV battery applications.

Symtec’s polyimide heaters feature etched-foil or wire-wound heating elements laminated between polyimide layers, delivering uniform heat distribution across custom geometries. We engineer heaters with integrated thermistors, thermocouples, RTDs, and thermal fuses for precise closed-loop temperature control. Whether you need a single prototype or production volumes of 100,000+ units, our vertically integrated manufacturing process ensures consistent quality and competitive lead times.

Technical Specifications

Substrate Material: Polyimide (Kapton®, and equivalent films). Thickness: As thin as 0.2mm (0.008”) total assembly. Max Operating Temperature: 200°C (392°F) continuous. Watt Density: Up to 10 W/cm² depending on application. Heating Element: Etched foil (copper, Inconel, stainless steel) or wire-wound (nickel-chromium). Voltage Range: Custom, from 3.3V DC to 480V AC. Dielectric Strength: Exceeds 1500V per MIL-I-24768. Adhesive Options: Pressure-sensitive adhesive (PSA), thermal bonding, or mechanical mounting.

Available features include integrated temperature sensors (thermistors, RTDs, thermocouples), thermal fuses for over-temperature protection, custom lead wire and connector terminations, zone heating with independently controlled circuits, and moisture-sealed construction for medical and outdoor environments. All heaters are manufactured to UL, CSA, and ISO 9001 standards.

Industries and Applications

Aerospace and Defense: Polyimide heaters maintain critical operating temperatures in avionics, satellite systems, radar assemblies, and unmanned aerial vehicles. Their thin profile and light weight make them ideal for applications where every gram matters, and their resistance to vibration and thermal cycling ensures reliability in extreme conditions.

Electric Vehicles and Battery Systems: EV battery modules require precise thermal management to optimize charge rates, extend cycle life, and ensure safety. Symtec polyimide heaters provide uniform pre-conditioning heat across battery packs, enabling reliable cold-weather starting and consistent performance across the full temperature range.

Medical Devices and Diagnostics: From point-of-care diagnostic instruments to surgical warming systems, polyimide heaters deliver the precise, biocompatible heating required by FDA-regulated devices. Their thin construction integrates seamlessly into portable and handheld medical equipment.

Semiconductor and Electronics: Polyimide heaters are used in wafer processing, thermal test fixtures, and electronics enclosures requiring precise temperature control in compact form factors. Their excellent dielectric properties and chemical resistance make them suitable for cleanroom and process-critical environments.

Ready to start your project?

Get a feasibility study done at no cost. Our engineers will review your application requirements and recommend the optimal polyimide heater design for your specific needs.