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Swaged High-Density Cartridge Heaters
Compact, rugged heaters engineered for tight fits and rapid heat transfer. Swaged magnesium oxide (MgO) insulation enables high watt density and long life in demanding molds, dies, platens, and hot‑runner manifolds.
- Up to 1400°F (760°C)
- Up to 150 W/in²*
- Dielectric > 1000V
- Ø 1/8" to 1"
- RoHS / REACH
Product Specs
| Specification | Details | Remarks |
|---|---|---|
| Diameter | 1/8″ to 1″ | Custom diameters available upon request |
| Lengths | Up to 24″ | Longer lengths may be engineered |
| Voltage | Up to 480V | Lower voltages available |
| Watt Density | Up to 400 W/in² | Dependent on sheath temperature |
| Sheath Material | 304 / 316 Stainless Steel | Other alloys upon request |
| Lead Types | Fiberglass Insulated, PTFE, Armored | High-temperature leads optional |
| Temperature Rating | Up to 1400°F (760°C) | Based on application conditions |
| Tolerance | ±2% on Resistance | Tighter tolerance available |
| Thermocouple Options | Type J, K, Grounded / Ungrounded | Built-in or separate thermocouple |
| Termination Styles | Leads, Pins, Quick-Disconnects | Custom termination upon request |
| Moisture Resistance | Epoxy Potting Available | Optional hermetic sealing |
Product Specs
| Specification | Details | Remarks |
|---|---|---|
| Diameter | 1/8″ to 1″ | Custom diameters available upon request |
| Lengths | Up to 24″ | Longer lengths may be engineered |
| Voltage | Up to 480V | Lower voltages available |
| Watt Density | Up to 400 W/in² | Dependent on sheath temperature |
| Sheath Material | 304 / 316 Stainless Steel | Other alloys upon request |
| Lead Types | Fiberglass Insulated, PTFE, Armored | High-temperature leads optional |
| Temperature Rating | Up to 1400°F (760°C) | Based on application conditions |
| Tolerance | ±2% on Resistance | Tighter tolerance available |
| Thermocouple Options | Type J, K, Grounded / Ungrounded | Built-in or separate thermocouple |
| Termination Styles | Leads, Pins, Quick-Disconnects | Custom termination upon request |
| Moisture Resistance | Epoxy Potting Available | Optional hermetic sealing |
Cartridge Heater Structure Diagram
Cartridge Heater Wiring Diagram
Even heating for long-lasting use
1. Before installation, use a multimeter to measure whether the heating element is powered on. If the multimeter measures no problem, then proceed with the installation. If not, please contact us.
2. The heating tube must be connected in the correct way. Wrong connection will cause slow heating and burn out of the heating tube. The two common connection methods are shown in the figure (please refer to)
Common Applications
Plastic Injection Molding
Used for heating nozzles, manifolds, and hot runner systems.
Packaging Equipment
Sealing bars, cutting tools, and thermoforming processes.
Medical Equipment
Sterilization systems, analytical devices, and laboratory tools.
Food Processing
Heat sealing, hot plates, and food handling machinery.
Semiconductor
Wafer processing, thermal testing, and precision heating.
General Industry
Die casting, metal forming, and other industrial heating needs.
Cartridge Heater Customization
Installation & Fit
- For longest life, use a tight, straight bore with surface finish ≤ 32 μin Ra.
- Typical interference fit target is 0.001″–0.003″ depending on diameter.
- Avoid set-screw points; use full-length contact.
- Ream rather than drill; remove burrs and chips.
- Apply thin film of thermal compound if permissible.
- Support leads with strain relief and avoid flexing at exit.
- Use closed-loop temperature control (PID + thermocouple).
Break-in & Operation
- Start at 50% power for 15 minutes to drive off moisture.
- Increase to operating setpoint while monitoring current draw.
- Never energize in free air; ensure proper heat sink.
- Periodically verify ground continuity and insulation resistance.
Elekheat Certification
FAQ: Cartridge Heaters — Metric & Imperial
Aim for a light interference fit. Typical diameter tolerance is −0.001\"/−0.003\" and the bore should be straight and reamed. A tighter fit improves heat transfer and lowers sheath temperature.
In some cases, yes. With superb heat transfer (e.g., aluminum tooling, generous contact, forced convection), higher watt densities may be acceptable. Validate with instrumentation and consult engineering.
For most applications, fiberglass leads are suitable up to ~842°F (450°C) at the exit; MGT leads handle higher temperatures. Add stainless braid or flexible conduit for mechanical protection.
Yes—Type J or K, grounded or ungrounded, at the end or mid‑section depending on geometry. The configurator lets you include this in the part number.
We'd love to hear from you
Contact Us
Thank you for your interest in our cartridge heaters!
Whether you’d like to learn more about product specifications, request a custom solution, or request a quote, we’re happy to assist you.
Reach us through
- +86 15996326879
- sale@elekheat.com
- 8:30 AM - 18:00 PM
