Ultra Thin Flexible Heaters

Sometimes the problem isn’t getting heat. It’s finding space for the heater.

Our Ultra-Thin flexible heaters are designed for applications where standard heaters are simply too bulky — tight enclosures, curved surfaces, lightweight assemblies, or components that can’t tolerate uneven heating.

Using polyimide (Kapton®) or silicone rubber constructions, these heaters can be built as thin as 0.22 mm while still delivering stable and uniform heat.

They’re commonly used in EV battery systems, medical devices, semiconductor equipment, optical instruments, and aerospace electronics.

Talk to an Engineer and Request a Datasheet!

 An Ultra-Thin flexible heater is a lightweight heating element designed for applications where traditional heaters are too bulky or rigid to fit properly.

Most designs use polyimide (Kapton®) film combined with etched foil heating circuits, which allows the heater to flex and maintain close thermal contact with curved or uneven surfaces. This helps improve heating efficiency and temperature uniformity, especially in compact electronic systems.

Ultra-Thin flexible heaters are commonly used in EV battery systems, ADAS sensor defogging, medical devices, semiconductor equipment, optics, and aerospace electronics, where fast thermal response and compact installation space are required.

Working on a Difficult Thermal Problem?

If you’re dealing with limited space, unusual surface materials, voltage constraints, or challenging temperature requirements, feel free to share your application details with us.

Even during the early design stage, we can often help recommend suitable heater structures, materials, or thermal approaches based on your requirements.

Send your application requirements to:
info@ptc-heater.com.tw

Engineered for performance in extreme environments.

Unlike standard off-the-shelf heating pads, KLC flexible heaters are designed to meet rigorous industrial standards:

• Ultra-Thin & Lightweight: Only 0.22mm thick, weighing ~0.04 g/cm² for easy integration.
• Rapid, Uniform Heating: Ensures consistent performance across surfaces.
• Wide Operating Range: Functions from -60°C to +200°C, supporting 1.5~600V AC/DC.
• Flexible & Durable: KLC’s polyimide heaters have passed rigorous 20,000-hour tests encompassing both continuous heating and rapid on/off cycling. 
• EMF-Free & Cost-Effective: Safe and budget-friendly for all industries.
• Versatile Shapes: Available in all sizes, including shapes with holes for custom fit... (More)

Our ultra-thin flexible heaters support a wide range of use cases, including: 

• Camera Lens Heater: Optical & Camera Thermal Solutions

• Electronics & Sensors: Moisture protection for electronics, PCB boards, and LCDs

• Automotive: Anti-fog and anti-ice solutions for EV ADAS, rear-view mirrors, battery systems

• Medical: Diagnostic device heating, incubator support, temperature stabilization

• Industrial & Aerospace: Battery pre-heating, sensor de-icing, snowmobile grips

• Computer equipments: IC chips/ PCB and… (More)                         

Selecting the right flexible heater depends on application requirements, power density, mounting conditions, and temperature control. Improper selection can lead to overheating, reduced lifespan, or system failure.

• Application: Define the heated object, material, and environment
• Size & shape: Heater should match the surface to avoid dry burning
• Electrical design: Voltage (1.5–600V) and power follow Ohm’s Law (P = V² / R)
• Power density: ≤0.8 W/cm² for adhesive mounting (PSA)
• Operation Temperature: -60°C to +200°C depending on design
• Control: External temperature controller required

Read the full Flexible Heater Selection Guide →

 
These technical FAQs help engineers design and select the right flexible heater for their application.

What is power density in a flexible heater?

Power density (W/cm²) is the heat output per unit area. For polyimide (Kapton) flexible heaters with adhesive mounting (PSA), it is typically limited to ≤0.8 W/cm². Higher values require mechanical clamping or improved heat dissipation. Clamping with a pressure plate is mandatory for power densities over 0.8 W/cm2 or operating temperatures above 110°C. This prevents the adhesive from softening and causing bubbles due to thermal expansion

How do I select voltage and resistance?

Flexible heater output follows Ohm’s Law (P = V² / R). KLC suggest selecting specifications based on “Temperature Rise Reference” and the resistance limits of the specific heater series. 

Can flexible heaters operate in open air?

No. Flexible heaters require direct contact with a surface. Flexible heaters are designed for direct thermal conduction and function most efficiently when tightly adhered to an object, as air has very low thermal conductivity

What affects heater performance?

Performance depends on thermal conductivity, mounting contact, airflow, insulation, and power density.

Is a temperature controller required?

Yes. Flexible heaters are not self-regulating. A temperature controller (e.g., PID) and over-temperature protection are recommended.

Need more technical details?

For in-depth information regarding installation SOPs, thermal resistance data, and advanced control configurations, please visit our  Complete Technical Q&A Page.

Get Custom Flexible Heater Support

Custom Flexible Heater Solutions

KLC specializes in custom flexible heater design and manufacturing. Custom specifications can be designed according to customer’s requirements. 

 We support engineers from concept to production, offering:

• Voltage, Wattage and temperature
• Custom shapes and sizes
• Optimized heating patterns
• Integrated sensors (NTC / RTD)
• Adhesive backing options
• Full engineering support

Contact us : info@ptc-heater.com.tw now!