Core Value: The Customized Flexible Tubular Heater is the ultimate solution for heating hot runner manifolds and complex mold geometries. Unlike standard rigid heating elements, this heater is engineered with a specialized annealing process and flexible internal structure, allowing it to be bent by hand or with simple tools directly into the manifold grooves at the installation site. This “install-and-bend” capability eliminates fitment errors caused by machining tolerances and removes the need for complex pre-ordering measurements. Available in Round or Square profiles for maximum heat transfer contact. BACKED BY 30+ YEARS MANUFACTURING EXPERIENCE and UNDERGOES MULTIPLE RIGOROUS QUALITY CHECKS for reliable, uniform heating.
- ✓ User-Bendable: Can be bent arbitrarily into complex 2D or 3D groove shapes on-site.
- ✓ Easy Installation: Simply press into the groove; no heavy machinery required.
- ✓ Square Profile Option: Provides >75% surface contact with the mold for superior heat transfer.
- ✓ High Watt Density: Capable of delivering concentrated heat for high-performance plastics.
- ✓ Uniform Heating: Precision winding ensures consistent temperature across the entire manifold.
- ✓ Durable Sheath: Stainless Steel or Nickel-plated braid withstands mechanical stress.
- ✓ Reliable Quality: 30+ YEARS MANUFACTURING EXPERIENCE ensures structural integrity.
- ✓ Quality Assured: UNDERGOES MULTIPLE RIGOROUS QUALITY CHECKS.
- ✓ Global Standards: CE, LVD, RoHS, ISO 9001 certified.
Technical Specifications & Performance Data
| Parameter | Standard Value | Customizable Range | Notes |
|---|---|---|---|
| Element Type | Flexible Tubular Heater | – | Hand Formable |
| Cross Section | 6.5mm / 8.0mm / 8.5mm | 6x6mm / 8x8mm Square/Other | Round or Square |
| Length | 300mm – 1500mm | Up to 3000mm | Can be cut/made to order |
| Power Rating | 300W – 2000W | High Watt Density 100w-20kw | Based on unfolded length |
| Voltage Rating | 230V AC | 12V – 480V | 50/60Hz compatible |
| Min Bending Radius | R10mm (Center) | – | Do not bend sharper than min |
| Surface Temp | Up to 700°C | – | Manifold Operating Temp |
| Sheath Material | Soft Annealed SS304 | Nickel / Chrome Steel | Designed for flexibility |
| Connection | M3/M4 Studs or Leads | Ceramic Connector | Cold zone customizable |
| Warranty | 1 Year Standard | Quality assured | COMPREHENSIVE QUALITY ASSURANCE |
Industrial Applications & Solutions
- Hot Runner Manifolds: The primary application. The flexible heater follows the milled channels of the manifold plate, providing heat to maintain plastic melt viscosity.
- Complex Mold Heating: Used in molds with irregular shapes where rigid straight heaters cannot fit.
- Packaging Machinery: Sealing bars with curved profiles. The heater can be contoured to match the sealing line perfectly.
- Textile Cutting Knives: Heating curved blades or cutting tools.
- Die Casting Platens: Maintaining temperature in metal casting dies with routed grooves.
- Semiconductor Processing: Heating vacuum chambers or plates with restricted access paths.
HT-Heater vs Standard Rigid Heaters
| Feature | HT-Heater (Flexible Type) | Standard Rigid Heater | Your Advantage |
|---|---|---|---|
| Installation | Bend on-site by hand | Pre-bent factory only | No measurement errors |
| Fitment | Self-adjusting to groove | Strict tolerance required | Perfect contact every time |
| Stocking | Stock straight, bend later | Stock specific shapes | Reduce inventory costs |
| Heat Transfer | Square Profile Available | Mostly Round | Better contact area |
| Manufacturing Experience | 30+ YEARS EXPERIENCE | New factories | Consistent annealing quality |
| Quality Assurance | MULTIPLE RIGOROUS QUALITY CHECKS | Simple continuity test | ZERO DEFECT DELIVERY |
Installation & Integration Guidelines
- Groove Dimensions: Ensure the manifold groove depth and width match the heater diameter. For 8mm heaters, a groove of 8.1mm is recommended for a press-fit.
- Installation Tool: We recommend using a soft mallet (rubber or plastic) to tap the heater into the groove. Do not use a metal hammer directly on the heater sheath, as this can damage the insulation.
- Bending Start: Start pressing the heater from the middle of the groove and work outwards towards the ends. This prevents the heater from springing back.
- Minimum Radius: Respect the minimum bending radius (typically 12-15mm). Bending too sharply can break the internal resistance wire.
Customer Success Stories
Case 1: Hot Runner System Manufacturer (Italy)
Application: Custom manifold systems.
Challenge: Standard pre-bent heaters often arrived with slight tolerance errors, not fitting the CNC-milled plates.
Solution: Switched to HT-Heater Flexible Tubular Heaters.
Results: ASSEMBLY TIME REDUCED BY 30%. “Being able to bend them into the groove ourselves guarantees a perfect fit every time. HT-Heater UNDERGOES MULTIPLE RIGOROUS QUALITY CHECKS.”
Case 2: Mold Repair Shop (USA)
Application: Repairing old injection molds.
Challenge: Difficulty sourcing replacement heaters for obsolete mold designs.
Solution: Stocking straight flexible heaters in various lengths.
Results: INSTANT REPAIRS. “We just grab a straight flexible heater and bend it to match the old mold. 30+ YEARS MANUFACTURING EXPERIENCE makes a difference.”
Case 3: Packaging OEM (South Korea)
Application: Curved sealing jaws.
Challenge: Uneven heating on curved surfaces.
Solution: Square profile flexible heaters.
Results: BETTER SEAL QUALITY. “The square profile transfers heat much better than round tubes. Great quality assurance.”
Pricing & Procurement Options
Standard Production: MOQ 10 pieces. BACKED BY 30+ YEARS MANUFACTURING EXPERIENCE ensures consistent quality. Discounts for 50+ units. Standard models in stock.
Lead Times: Standard: 7-10 days production. Custom: 10-15 days. Samples: 5-7 days. Rush service available for urgent requirements.
Global Logistics: Worldwide shipping via UPS, DHL, FedEx, EMS, TNT or the shipping agent as your request. Every shipment backed by 30+ YEARS MANUFACTURING EXPERIENCE.
Sample Orders: Available for testing. Contact sales for pricing. All samples UNDERGO MULTIPLE RIGOROUS QUALITY CHECKS.
Global Certifications & Compliance
- CE Marking
Conforms to European directives - LVD Compliance
Electrical safety requirements - RoHS Compliant
Environmentally safe materials - ISO 9001
Rigorous quality control processes
Quality Documentation: Certificate of Conformity and resistance test reports available. Every unit UNDERGOES MULTIPLE RIGOROUS QUALITY CHECKS before shipment.
Comprehensive After-Sales Support
Warranty: 1 Year Standard Warranty against manufacturing defects.
Technical Support: Installation videos and groove dimension guides available.
Service Network: BACKED BY 30+ YEARS MANUFACTURING EXPERIENCE. Global technical support available.
Ready to Simplify Your Mold Heating?
Next Steps:
- 📧 Request Custom Quote – Specify length and diameter
- 🔧 Free Installation Guide – How to bend properly
- 📦 Order Test Samples – Try the flexibility yourself
- 📞 Contact Heating Experts – Response within 2 hours
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