How to Customize a PI Heating Element: Step-by-Step Guide

Custom PI (Polyimide) heating elements are widely used in electronics, automotive, aerospace, medical equipment, and industrial temperature-control devices. Their ultra-thin, flexible, and high-precision characteristics make them an ideal choice for modern heating applications.

This guide explains the full customization process—design, materials, power configuration, etching, SMT mounting, testing, and mass production—so you can confidently develop a PI heating solution for your product.

1. Step 1 — Define Your Application Requirements

Every PI heater begins with a clear definition of usage conditions. This affects voltage, power density, circuit layout, and material selection.

Key parameters to provide:

Application scenario: battery heating, medical device, sensor, camera, EV, aerospace, etc.
Target temperature: e.g., 40–80°C
Working environment: humidity, pressure, chemical exposure, vibration
Power source: DC / AC, voltage range (3.7V / 5V / 12V / 24V…)
Space limitations: thickness, width, shape of install area

2. Step 2 — Provide Size, Shape & Layout

PI heaters can be made in almost any geometry:

Rectangular
Round
Annular
3D Curved Shapes
Custom CNC-cut patterns

If your design has holes, slots, or irregular edges, these can also be etched precisely.

Tip: Provide a 2D CAD file (DXF/AI/STEP) for the fastest accuracy.

3. Step 3 — Determine Voltage, Power & Resistance

The core electrical design of a PI heater comes from Ohm’s law:

P = V² / R

You choose based on your needs:

Low-voltage (3.7V–12V) → drones, wearables, consumer electronics
Medium-voltage (12V–24V) → automotive, sensors
High-voltage (48V–220V) → industrial equipment

Engineers will calculate the track width, spacing, and foil thickness to meet your desired watt density.

4. Step 4 — Choose Materials: PI Film, Adhesive & Foil

Typical structure:

Polyimide film thickness: 12.5μm / 25μm
Copper foil: 12μm / 18μm
Adhesive: high-temp acrylic or epoxy
Reinforcement layers: fiberglass, aluminum foil (for heat spreading)

Tip: Use thicker PI or FR film for >80°C applications.

5. Step 5 — Etched Foil Circuit Design

PI heaters use chemical etching to form extremely fine heating circuits.

Advantages of etched foil:

Very uniform heat distribution
Ultra-thin (<0.3 mm)
Bendable and flexible
High precision—track width can be 0.2–0.5mm

6. Step 6 — Add SMT Thermistors, Thermocouples, or Sensors

Modern PI heaters often integrate sensing components:

Options:

SMT NTC thermistor
PTC thermistor
Digital temperature sensor (e.g. DS18B20)
K-type thermocouple

These sensors allow precise temperature feedback to a controller.

New Technology: Some manufacturers support full SMT process on PI heaters, including connectors and control ICs.

7. Step 7 — Select Connector & Terminal Type

Common choices:

Golden Finger (best for reliability)
JST / Molex connectors
Solder Pads
FPC Connectors

Gold-finger interfaces improve durability and conductivity, especially for high-cycle applications.

8. Step 8 — Prototype, Testing & Certification

Before mass production, you will receive samples to test:

Resistance measurement
Temperature uniformity
Power stability
Aging test
Insulation & dielectric strength

Products may meet:

ISO9001
IPC-2223
KC / CE / UL standards

9. Step 9 — Mass Production & Delivery

Once the prototype is approved, production begins:

PI sheet cutting
Circuit etching
Lamination
SMT assembly
Final testing
Packing & shipping

Large-scale output ensures consistency for OEM customers.

Conclusion

Customizing a PI heating element requires expert engineering and precise manufacturing. From power design to sensor integration, each step influences performance and reliability. With advanced technologies such as etched foil circuits, SMT thermistors, gold-finger connectors, and strict quality control, modern PI heaters deliver superior temperature control for high-tech industries.