How to Submit a Custom Heater Design: Specs Our Engineers Need
Are you an OEM or designer looking to integrate a precision thick-film heater into your product? Whether it’s for an industrial appliance, EV thermal system, or medical device, successful integration starts with the right specifications.
At Datec Coating Technologies, we’ve streamlined the process for submitting custom heater designs. Providing detailed specs upfront ensures quicker quotes, better performance, and smoother collaboration. Here’s everything our engineers need to know to bring your custom heater from concept to production.
Why Detailed Specs Matter
Understanding your project’s technical and operational needs helps us deliver a reliable, custom-designed heater that:
- Matches your thermal performance expectations
- Integrates seamlessly with your assembly
- Meets regulatory and endurance requirements
Incomplete specifications lead to delays, extra design cycles, and overspecification—potentially costing time and money. Here’s a breakdown of the critical information required:
1. Performance Requirements
🔹 Target Operating Temperature & Uniformity
Specify:
- Minimum & maximum temperature—e.g., 20–200 °C
- Uniformity tolerance—e.g., ±2 °C across heated area
Example: “Maintain 180 °C uniformly across a 150 mm × 150 mm aluminum plate.”
🔹 Ramp Rate & Response Time
How quickly should the heater reach its setpoint?
- E.g., “Heat from ambient to 150 °C in <60 seconds.”
🔹 Operating Environment
Specify conditions such as:
- Ambient temperature range (–40 °C to 85 °C)
- Exposure to moisture, oils, chemicals
- Continuous duty vs. intermittent cycles
2. Electrical Specifications
🔹 Input Voltage & Power Needs
- Preferred voltage: e.g., 12 V, 24 V, or 800 V pack voltage
- Maximum allowable current
🔹 Power Density / Wattage
- Total power or W/in²—e.g., 30 W/in² over a defined area
🔹 Preferred Electrical Connections
- Leads, solder tabs, wire gauge, connectors
3. Mechanical Details
🔹 Substrate Material & Geometry
Choose from:
- Aluminum: lightweight, excellent conductivity (see IntegrAL® aluminum heater)
- Stainless steel: durable and bendable (see Hi‑Temp TF stainless steel)
- Mica, glass, or custom materials
Need specifics on mica-based heaters? Refer to our mica-TF® mica-based heater page.
Include CAD files or drawings showing thickness, mounting points, cutouts, and heating zones.
4. Thermal Control & Monitoring
🔹 Control Strategy
Will the heater use:
- Simple on/off cycling?
- PID or advanced feedback control?
- External sensors / thermostats?
🔹 Sensor Integration
Alert us if you require printed RTDs or thermistors for in-situ measurements.
5. Environmental & Regulatory Compliance
🔹 Certifications
Known standards like UL, CE, RoHS, or REACH? Let us know early.
🔹 Endurance Testing
Expect testing like:
- ≥ 100,000 hours at operational temperature
- Thermal shock, vibration, humidity
6. Volume & Production Info
Provide:
- Initial prototyping quantity: e.g., 5–10 units
- Annual planned volume: e.g., 500–5,000 units/year
- Budget constraints and anticipated lead times
These details allow us to recommend efficient production methods and pricing tiers.
7. Support Documents & References
Send us (if needed, after NDA):
- CAD drawings (STEP, DXF, PDF)
- Photos or samples of similar heaters
- System block diagrams showing heater placement
- Bill of Materials (if available)
How It Works: Step-by-Step
- Submit Specs via Contact Form
Use the Contact Us form to reach out to us via email; after which we will send you an introduction and an Application Form. - Engineering Evaluation
We review your specs during internal scoping calls, clarifying performance, electrical, and mechanical needs. - Design & Prototype
We produce a prototype and run testing in our North American lab, covering thermal, electrical, and cycle validation. - Sample Approval
Receive samples for fit, form, and function testing on your side. - Pilot & Production
Confirm prototype performance, then move to pilot and full-scale manufacturing, supported with testing documentation and compliance certifications.
Summary Table: What You Need to Provide
| Specification Area | Examples to Include |
|---|---|
|
Temperature |
150 °C uniform, ramp in 60 s, ambient –20 °C to 80 °C |
|
Electrical |
800 V input, max 10 A, 30 W/in² |
|
Mechanical |
200 mm × 200 mm aluminum, 2 mm thick, include mounting holes |
|
Control/Sensors |
PID control with 2 printed thermistors |
|
Standards |
UL recognized, RoHS / CE compliant |
|
Volume & Timeline |
10 prototypes, 1,000 units/year, delivery Q4 2025 |
Final Thoughts
Equipping your heater design with clear, complete specs ensures swift deployment, reliable performance, and long-lasting product success. By aligning early with Datec’s engineering team, you can avoid common pitfalls and launch with confidence.
Ready to start? Visit our Custom OEM Heating Solutions page and contact us today.