Wire Wound Heaters

Wire wound heaters can be made with two insulation materials: silicone rubber and butyl rubber. The resistance material is stranded resistance wire, such as Ni-Chrome, Copper/nickel or Balco, which produces heat when current is applied to the circuit. 

Wire wound circuits are normally less expensive to make in small quantity than etched foil heaters because we do not have to create an artwork for the design. 

The heater pattern is laid out via computer program and a pin board is constructed. Resistance wire is then strung between these pins.

Silicone rubber is then placed on both sides of the resistance wire and vulcanized together to secure the wire and form an insulated flexible heater. 

Larger heaters are more economical in wire wound construction rather than etched foil because no material is lost; with etching, up to one half of the material is thrown away. 

Wire wound heaters are very flexible and heaters can be designed to expand readily as heat is applied.

Wire wound heaters are versatile in design and can be outfitted with built–in thermostats, thermocouples, fuses, vulcanized to heat sinks and fitted with wiring harnesses.

Heaters can be vulcanized to metal surfaces or have pressure sensitive adhesive applied for mounting. 

Wire wound heaters can have attachment devices applied such as grommets, Velcro, boot hooks and built-in straps. They can also be constructed with holes and cut outs and with shaded watt density for even heating, dual voltage heaters and many other features.