Cylindrical electric heating elements with high watt density for fast, precise heating in tight spaces.
High-density cartridge heaters —also known as cartridge heating elements, high-power tubular cartridges or, in their international technical terminology, high-performance cartridge heaters— are industrial electric heating elements built to deliver large amounts of thermal power in a very small volume. What sets them apart from conventional cartridge heaters is their high watt density, which reaches values of up to 50 W/cm² (320 W/in²) at the sheath surface.
Their construction is based on a chromium-nickel stainless steel tube with a NiCr 8020 resistance wire wound on a ceramic core and insulated with highly compacted magnesium oxide (MgO). This compaction is what enables the high heat transfer between the wire and the sheath, and it is what distinguishes a high-density cartridge heater from traditional low-density (non-compacted) cartridge heaters.
| Attribute | Standard | Integ. thermocouple | PT100 sensor | Ø 4.0/4.5 bipolar | Low voltage | Sensing tip | Low-density |
|---|---|---|---|---|---|---|---|
| Main application | Molds, blocks and nozzles; general use | Temperature control without an external probe | Accuracy and traceability (medical, pharma, food) | Very small parts or narrow bores | Enhanced electrical safety / low voltage | Ambient temperature control (sealing) | Less demanding applications in watt density |
| Sheath | CrNi steel · base welded in protective atmosphere | CrNi steel · base welded in protective atmosphere | CrNi steel · base welded in protective atmosphere | CrNi steel · laser-welded base | CrNi steel · laser-welded base | CrNi steel · base welded in protective atmosphere | Stainless steel or brass · crimped base · opt. leak-tight weld |
| Insulation | Pure highly compacted MgO | Pure highly compacted MgO | Pure highly compacted MgO | Pure compacted MgO | Pure compacted MgO | Pure highly compacted MgO | Pure compacted MgO |
| Resistance wire | NiCr 8020 | NiCr 8020 | NiCr 8020 | NiCr 8020 | NiCr 8020 | NiCr 8020 | NiCr 8020 |
| Leads | 300 mm (12") nickel wire over fiberglass · ceramic seal | 500 mm (20") heating + 500 mm (20") thermocouple · 480 mm (19") sleeve | 500 mm (20") heating + 500 mm (20") PT100 (PTFE) · 480 mm (19") sleeve | Nickel-PTFE · exit through head | 250 mm (10") direct · opt. dual-side | 300 mm (12") heating + 300 mm (12") thermocouple · 280 mm (11") sleeve | Nickel-fiberglass +350 °C (660 °F) · nickel-PTFE +260 °C (500 °F) · silicone +180 °C (355 °F) |
| Diameters | 6.5–20 mm · 1/4"–5/8" | 6.5–20 mm · 1/4"–5/8" | 6.5–20 mm · 1/4"–5/8" | 4.0 · 4.5 mm · 5/32"–3/16" | 4.5 mm · 3/16" (4.0 special) | 6.5 mm · 1/4" | To order |
| Dimensional tolerance | −0.01 to −0.05 mm · −0.0004 to −0.0020" (by Ø) | −0.01 to −0.05 mm · −0.0004 to −0.0020" (by Ø) | −0.01 to −0.05 mm · −0.0004 to −0.0020" (by Ø) | −0.01 to −0.03 mm · −0.0004 to −0.0012" | −0.01 to −0.03 mm · −0.0004 to −0.0012" | −0.01 to −0.03 mm · −0.0004 to −0.0012" | ± 0.10 mm (± 0.004") |
| Lengths | 40–300 mm · 1½"–12" | 40–300 mm · 1½"–12" | 35–300 mm · 1 3/8"–12" | 20–100 mm · 3/4"–4" | 40–100 mm · 1½"–4" | 40–60 mm · 1½"–3" | 50–4,000 mm · 2"–157" |
| Length tolerance | ≤100 → ±2 · 100–300 → ±5 mm (±0.08"–0.20") | ≤100 → ±2 · 100–300 → ±5 mm (±0.08"–0.20") | ≤100 → ±2 · 100–300 → ±5 mm (±0.08"–0.20") | ≤100 → ±2 mm (±0.08") | ≤100 → ±2 mm (±0.08") | ≤100 → ±2 mm (±0.08") | ± 1.5 % · min. ± 2 mm (± 0.08") |
| Voltage | 230 V | 230 V | ≤230 V | ≤230 V | 24 V · max. 48 V | 230 V | 230 V / 400 V |
| Power | 100–4,000 W | 100–4,000 W | ≤2,000 W | ≤200 W | 63–160 W | 115–300 W | To order |
| Power tolerance | ±10 % | ±10 % | ±10 % | ±10 % | ±10 % | ±10 % | +5 % / −10 % |
| Max. watt density | 50 W/cm² (320 W/in²) | 50 W/cm² (320 W/in²) | 50 W/cm² (320 W/in²) | 20 W/cm² (130 W/in²) | — | 50 W/cm² (320 W/in²) | 5 W/cm² (32 W/in²) |
| Max. sheath temp. | 750 °C (1,380 °F) | 750 °C (1,380 °F) | 750 °C (1,380 °F) | 260 °C (500 °F) | — | 750 °C (1,380 °F) | 500 °C (930 °F) stainless · 300 °C (570 °F) brass |
| Max. current | — | — | — | 4.0 A | — | — | — |
| Temperature sensor | — | Thermocouple L / J / K · base · floating | PT100 DIN EN 60751 cl. B · base | Optional thermocouple · head | Optional thermocouple | Thermocouple in tip · senses the surroundings | — |
| High voltage (HV) | 1,500 V-AC | 1,500 V-AC | — | <48 V → 500 / ≥48 V → 1,000 V-AC | — | — | 1,500 V-AC |
| Insulation resistance | ≥5 MΩ at 500 V-DC | ≥5 MΩ at 500 V-DC | — | ≥5 MΩ at 500 V-DC | — | — | ≥2 MΩ at 500 V-DC |
— not specified or not applicable · Reference data per manufacturer datasheets. Special versions are confirmed subject to technical review.
The base and most widely used configuration, designed for the most demanding operating conditions. They are the evolution of conventional low-density cartridge heaters with a brass or steel sheath: a recommended watt density of up to 50 W/cm² (320 W/in²) and operating temperatures of up to 750 °C (1,380 °F) ensure optimal performance and quality across a wide range of thermal processes.
| Dimension | Tolerance |
|---|---|
| Ø 6.5 · 8 mm · 1/4"–5/16" | −0.01 to −0.03 mm (−0.0004 to −0.0012") |
| Ø 10–16 mm · 3/8"–5/8" | −0.02 to −0.04 mm (−0.0008 to −0.0016") |
| Ø 20 mm · 3/4" | −0.03 to −0.05 mm (−0.0012 to −0.0020") |
| Length ≤ 100 mm · ≤ 4" | ± 2 mm (± 0.08") |
| Length > 100–300 mm · 4"–12" | ± 5 mm (± 0.20") |
Recommended when there is no room in the part to fit a separate probe. The thermocouple is integrated into the cartridge heater itself and closes the control loop directly. Depending on the application, the measuring point can be located at the base, in the middle zone or at any other point; the electrical configuration can be floating (potentialfrei) or grounded. The most common types are L / J (Fe-CuNi) and K (NiCr-Ni); other types on request. Standard items are kept in stock and delivered within 24–48 h.
| Dimension | Tolerance |
|---|---|
| Ø 6.5 · 8 mm · 1/4"–5/16" | −0.01 to −0.03 mm (−0.0004 to −0.0012") |
| Ø 10–16 mm · 3/8"–5/8" | −0.02 to −0.04 mm (−0.0008 to −0.0016") |
| Ø 20 mm · 3/4" | −0.03 to −0.05 mm (−0.0012 to −0.0020") |
| Length ≤ 100 mm · ≤ 4" | ± 2 mm (± 0.08") |
| Length > 100–300 mm · 4"–12" | ± 5 mm (± 0.20") |
Tell us about your use case and our engineering team will help you choose the optimal solution.
For processes where accuracy and traceability are critical (medical, pharmaceutical, food). Custom build only. The sensor is always placed in the base zone; for technical reasons, the area around the measuring point is unheated, and to compensate for the resulting temperature gradient in the sheath, the cartridge heater is reinforced with extra power (boost) in the zone immediately around the measuring point.
| Dimension | Tolerance |
|---|---|
| Ø 6.5 · 8 mm · 1/4"–5/16" | −0.01 to −0.03 mm (−0.0004 to −0.0012") |
| Ø 10–16 mm · 3/8"–5/8" | −0.02 to −0.04 mm (−0.0008 to −0.0016") |
| Ø 20 mm · 3/4" | −0.03 to −0.05 mm (−0.0012 to −0.0020") |
| Length 35–300 mm · 1 3/8"–12" | ≤100 → ±2 · 100–300 → ±5 mm (±0.08"–0.20") |
A high-density compacted cartridge heater with flexible PTFE-insulated nickel leads that exit directly from the cartridge body. Especially suited for heating very small parts and extremely narrow bores where standard diameters do not fit. Special build only. It can optionally include a thermocouple with the measuring point at the head.
| Dimension | Tolerance |
|---|---|
| Ø 4.0 / 4.5 mm · 5/32"–3/16" | −0.01 to −0.03 mm (−0.0004 to −0.0012") |
| Length 20–100 mm · 3/4"–4" | ± 2 mm (± 0.08") |
For SELV operation or 24 V systems. The current return runs through the cartridge sheath itself, which limits the maximum voltage to 42 V (within Europe, protective voltages of up to 48 V are partly allowed). Power varies within the technical possibilities. Standard items are kept in stock; they can also be custom built. Optionally with an integrated thermocouple.
| Dimension | Tolerance |
|---|---|
| Ø 4.5 mm · 3/16" (4.0 special) | −0.01 to −0.03 mm (−0.0004 to −0.0012") |
| Length 40–100 mm · 1½"–4" | ± 2 mm (± 0.08") |
The thermocouple sits in a reduced extension (the "tip") of the cartridge heater, so it is no longer next to the heating coil —as is the case with standard cartridge heaters with an integrated thermocouple. The decisive advantage is that these cartridge heaters do not measure their own temperature but that of the surroundings or the heated part, which allows more precise and uniform process temperature control. A common solution in heat sealing. Standard items in stock; custom builds also available.
| Dimension | Tolerance |
|---|---|
| Ø 6.5 mm · 1/4" | −0.01 to −0.03 mm (−0.0004 to −0.0012") |
| Length 40–60 mm · 1½"–2 3/8" | ± 2 mm (± 0.08") |
An economical alternative to the high-density cartridge heater (hochverdichtet) for simple use cases, with a maximum watt density of 5 W/cm² (32 W/in²) and an operating temperature of up to 500 °C (930 °F). It is suitable for undemanding applications but is not recommended when the tool is subject to heavy mechanical stress (for example, vibration). Custom builds available: other dimensions, voltages, mounting features, unheated zones and power distributions on request. Sheath in stainless steel (up to 500 °C / 930 °F) or brass (up to 300 °C / 570 °F).
| Dimension | Tolerance |
|---|---|
| Diameter (depending on grinding) | ± 0.10 mm (± 0.004") |
| Length 50–4,000 mm · 2"–157" | ± 1.5 % · min. ± 2 mm (± 0.08") |
As a manufacturer of high-density cartridge heaters, we meet each customer's individual needs and produce custom cartridge heaters in diameters from 4.0 to 20 mm (5/32"–3/4"). All requirements are considered and implemented in development and production within our technical possibilities: different voltages, tailored power boost at the ends, separately switchable heating zones and an integrated PT100 or thermocouple.
| Parameter | Range on request |
|---|---|
| Diameter | 4.0 to 20 mm · 5/32"–3/4" |
| Length | 20 to 3,000 mm · 3/4"–118" |
| Voltage | 6 V to 500 V |
| Max. watt density | 50 W/cm² (320 W/in²) |
| Max. sheath temp. | 750 °C (1,380 °F) |
| Power tolerance | ± 10 % · ± 5 % by agreement |
Especially in plastics and packaging, uniform heat delivery is required along the entire element mounted in the tool (sealing jaws, platens, heated bars). By boosting the end zones, the heat delivery is individually adjusted to the desired effect.
Design with a three- and four-wire system (heating zones): by switching the phases across the windings arranged in parallel, the total power is regulated as needed. Available from Ø 12.5 mm (1/2").
PT100 or thermocouple (types L / J Fe-CuNi and K NiCr-Ni), in a floating (potentialfrei) or grounded version, with the measuring point in the position the process requires.
Multiple connection options, angled heads and side exits, various power leads, metal protective tubes, fiberglass sleeves, stainless steel braid, and more.
Thermal performance and service life depend directly on the mechanical fit between the cartridge heater and its bore. Excessive clearance prevents heat conduction, overheats the internal winding and drastically shortens the component's life. Recommended bore tolerance: ISO H7.
| Cartridge nominal Ø | Bore tolerance (H7) |
|---|---|
| > 3 to 6 mm (0.12"–0.24") | +0.012 / −0 mm (+0.0005") |
| > 6 to 10 mm (0.24"–0.39") | +0.015 / −0 mm (+0.0006") |
| > 10 to 18 mm (0.39"–0.71") | +0.018 / −0 mm (+0.0007") |
| > 18 to 30 mm (0.71"–1.18") | +0.021 / −0 mm (+0.0008") |
Any process that requires generating concentrated thermal power in a small bore.
Nozzles, hot runners, tips and heated inserts.
Sealing jaws, welding wheels, platens for film.
Distributor blocks and extrusion heads.
Thermal bonding, tube welding, precision instrumentation.
Small ovens, primary packaging sealing, blister machines.
Longitudinal and cross sealing jaws.
Vulcanizing presses, thermoforming molds.
Small ovens, thermal baths, test equipment.
Up to 50 W/cm² (320 W/in²) at the sheath surface, with temperatures of up to 750 °C (1,380 °F) —5 to 10 times more than a conventional low-density cartridge heater. The low-voltage and Ø 4 mm (5/32") versions work at lower densities, typically 20 W/cm² (130 W/in²).
The integrated thermocouple measures the temperature of the cartridge heater itself (protecting against overheating). The sensing tip, physically separated from the heated zone, measures the temperature of the surroundings or the heated part —the most precise option for controlling process temperature (e.g. sealing jaws).
The PT100 offers higher accuracy and better repeatability, ideal for pharmaceutical, food and medical applications with critical traceability. Its range is lower (up to ~600 °C / 1,110 °F). Above that temperature, or where exact accuracy is not required, the thermocouple is more practical and economical.
ISO H7 is recommended. For Ø 10 mm (3/8"), the bore is machined to Ø 10 +0.018 / −0 mm (+0.0007"). Larger clearance reduces heat transfer and accelerates wear; above 400 °C (750 °F) it is advisable to use thermal assembly paste.
Yes. Power boost concentrates power at the ends or specific zones. Multi-zone heating with independent windings is also possible, available from Ø 12.5 mm (1/2").
Standard configurations Ø 6.5–20 mm · 1/4"–3/4" (standard or with thermocouple) are kept in stock in Barcelona and delivered within 24–48 h. Special versions require dedicated manufacturing with a lead time depending on the project.
Tell us about your use case and our engineering team will help you choose the optimal solution.
