Flexible Heaters
We design and manufacture custom flexible heaters and complete thermal management solutions.
Trusted for over 40 years
NEL Technologies is a specialist flexible heater manufacturer with over 40 years of experience designing thin, lightweight heating elements that conform to curved, irregular or spaceconstrained surfaces. Unlike rigid heating elements, flexible heaters deliver controlled, uniform heat where conventional heaters cannot fit or perform, making them essential in applications where space, weight and reliability are critical.
Our heaters are trusted across medical diagnostics, aerospace and satellite systems, Formula 1, electronics, food processing and industrial applications, sectors where repeatability, compliance and reliability are non-negotiable.
Our heaters are engineered to bond directly to any surface, or to integrate with a custom heatsink or heat-spreading substrate, depending on your thermal and mechanical requirements.
Custom Flexible Heater Design
We use high-precision etched foil heater technology to create heating elements tailored to your component, environment and performance requirements. Using AutoCAD Fusion 360, our engineers develop custom solutions matched to your required size, shape, voltage, wattage and heating profile, from simple rectangular heater mats to complex irregular geometries. Each heater is designed with the full thermal system in mind.
Our engineers work with you during the design phase to ensure heater performance, integration, sensor placement and thermal protection are fully considered before manufacture begins. This design-led approach helps avoid specification errors and reduces the risk of field failures.
Flexible heaters are available in multiple dielectric options with operating temperature ranges from -195°C to +230°C, depending on heater type and application.
By combining etched foil heaters with thermal protection systems and heatsink design, we supply fully assembled, electrically tested heater units, from rapid prototyping through to scalable production.
We specialise in:
High precision etched metal foil technology
Polyimide heaters with low-moisture-retention dielectrics
Kapton® heaters manufactured using DuPont-supplied dielectric
Silicone rubber heaters, including wear-pad constructions
Polyester heaters using optical-grade dielectric
Integrated thermostats, thermal fuses or thermistors
Custom shapes engineered to bond to any surface or heatsink
Rapid prototyping — prototypes available within 48 hours
Production quantities with full traceability
Operating temperature range from -195°C to +230°C
Specialists in Flexible Heaters
Employee-owned and based in Newcastle, UK, NEL Technologies has designed and manufactured custom flexible heaters for over 40 years. From medical diagnostics and aerospace to satellite systems, our heaters deliver reliable thermal performance in the most demanding applications. ISO 9001/14001 certified. UL approved.
Frequently Asked Questions — Flexible Heaters
What are flexible heaters used for?
Flexible heaters provide controlled, uniform heating across a surface or component. They are used in applications where space is limited, shapes are irregular, weight must be minimised, or precise temperature control is required. Common applications include medical diagnostic instruments, aerospace and satellite thermal management, food processing equipment, and electronics enclosures.
What types of flexible heaters does NEL manufacture?
NEL designs and manufactures polyimide (Kapton®) heaters, silicone rubber heaters, polyester heaters and specialised solutions using alternative dielectric materials. Our core technology is etched foil heating elements, which offer superior heat distribution and repeatability compared to wire-wound alternatives. Wire-wound constructions are also available where required.
How do I choose between polyimide and silicone rubber heaters?
Polyimide (Kapton®) heaters are thinner and lighter, making them ideal for low-profile, weightsensitive and precision applications — they can be as thin as 0.2 mm total thickness. Silicone rubber heaters are thicker and more durable, offering better resistance to moisture, vibration and mechanical handling. The right choice depends on your operating temperature, environment and mounting method — contact our engineering team to discuss your specific application.
What temperature ranges are available for flexible heaters?
Our flexible heater range spans -195°C to +230°C across all heater types. Polyimide heaters typically operate from approximately -200°C to +200°C, while silicone rubber heaters suit environments from around -60°C to +230°C. The achievable range for your application depends on the dielectric material, heater construction and operating conditions.
Can flexible heaters be supplied in custom shapes and sizes?
Yes. Flexible heaters can be manufactured in virtually any shape and size, including complex irregular geometries. NEL’s engineers use AutoCAD Fusion 360 to design heaters matched to your exact dimensional, voltage and wattage requirements, with lead assemblies, connectors and protection components included as needed.
How are flexible heaters mounted or bonded?
Flexible heaters can be bonded directly to a surface using pressure-sensitive adhesive, or mechanically fastened to a custom heatsink or heat-spreading substrate. The bonding method is selected during the design phase to ensure reliable thermal contact and long-term adhesion in your specific operating environment.
Can heaters be supplied with temperature control or protection devices?
Yes. NEL flexible heaters can be supplied with integrated thermostats, thermal fuses or thermistors for closed-loop temperature control and over-temperature protection. Sensor type and placement are determined during the design phase to ensure accurate monitoring and safe operation.
Are flexible heaters suitable for prototyping and production?
We support both rapid prototyping and volume production. Prototype heaters can be available within 48 hours depending on design complexity. The same etched foil process and tooling are used from prototype through to series production, ensuring consistent performance at every stage.
What information is needed to start a flexible heater project?
To begin, provide your application details, operating temperature range, target voltage and wattage, available size and shape envelope, and preferred mounting method. Any information about the operating environment (humidity, vibration, chemical exposure) helps our engineers recommend the most suitable heater construction. Get in touch here to start the conversation.