Flexible Heater Circuit Assembly
Custom Flex Heater Assembly and Prototyping
Flexible heater assemblies have a simple design, yet are used in advanced technologies for automotive, aerospace, medical, and portable electronics. Thin and lightweight, they provide excellent heat transfer and can be fabricated in virtually any shape or size to conform to a surface area. The material, adhesives, cable or wire termination, and additional components are specified based on your application.
Tramonto Circuits is a custom flex heater assembly manufacturer with a historical quality ratio of over 99%. We can work from your drawing and 3D model, or design and fabricate custom technologies, including prototypes for product development. Every flexible heater circuit assembly design undergoes a DFM review with our engineers, with your final approval before production.
Some Key Points
- Custom flex heater assembly design services
- Silicone and polyimide materials
- Terminated based on your connection requirements – 2 wires, 2 wires with thermistor, or ZIF connector
- Integrated thermistors, thermocouples, and other sensors as required for temperature monitoring
- Flex heater circuit assembly prototypes
Request a Quote
Receive a quote for most projects within 24 hours. Engineers respond to your inquiry and are available to answer questions and discuss design specifications.
Design Considerations for Flex Heater Assemblies
Every heater assembly is custom designed to meet your specifications for mechanical size, voltage, and wattage. Customer design submissions and custom flex heater assemblies designed by our engineers undergo a Design for Manufacturability (DFM) Assessment to verify it meets power, temperature, and functionality requirements. We offer prototyping services and functional testing to support product development.
Material and Adhesives
The heater material depends on what you are heating and the temperature requirements of the application. Silicone rubber is recommended for high-temperatures and testing environments due to its robustness. Temperature and application also dictate the adhesive and heat spreaders recommended for your assembly.
Connectors and Termination
Customers can specify the wire or cable length and termination method. For custom designs, our engineers determine appropriate lengths and methods based on your application. Flex circuit heater assemblies with a ZIF connector are tested to ensure the pattern fits the connection point in your product.
Strain Relief
Polyimide flex heater assemblies have a layer of flexible epoxy placed over solder joints to add robustness to the design.
Temperature Monitoring
Tracking thermal loads can be addressed via a thermistor or thermocouple. The controller size and flex heater assembly placement are factors in determining which option is appropriate.
Industries Served
Exceeding Quality Standards Since 2008
Tramonto Circuits is ISO 9001:2015 Certified and manufactures all circuits and flexible heater circuit assemblies in compliance with IPC ClassI, II, or III specifications. Our thorough engineering review and quality check processes have resulted in consistent quality and low return rates since 2008.
On-Time Delivery
Quality Ratio
24-Hour Quotations
Some of Our Happy Customers
A Manufacturing Process You Can Trust and Communication Every Step of the Way
With Tramonto Circuits, you are never left wondering about the status of your flex heater assembly project. Our collaborative and responsive engineering team keeps you informed every step of the way.
Order Submission and Acknowledgement
Submit your Gerber files, bill of materials, and desired quantity. We provide a response within 24 hours of receipt.
Design Review
Engineers conduct a DFM assessment of your design. If issues are identified, we contact you to discuss recommendations.
Timeline and Delivery Conformation
Receive a delivery date two days after design approval. We have a 98.15% success rate for on-time delivery.
Production and Shipping
Your circuits are fabricated, tested, and assembled in-house at our USA facility. Orders ship via UPS or FedEx.
Frequently Asked Questions
We specialize in manufacturing custom flex heater assemblies. For your convenience, customers can place blanket orders to have assemblies shipped in specified quantities and intervals.
Orders of any size are welcome. If you have questions about volume discounts, please include an inquiry with your design submission.
There are two insulating substrates used in flex heaters: silicone and polyimide. The type of material selected for your heater assembly depends on the temperature requirements of the application. Silicone can handle higher temperatures than polyimide, typically up to 220°C.
In silicone heaters, the assembly components are laminated between the material layers. Polyimide heaters have assembly components soldered towards the edge of the heater.
It is not typical to combine materials. In rare cases, we have fabricated flex heater assemblies with unique characteristics based on the customer’s request.
How do you attach components to a flex heater assembly?
