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High-Density Cartridge Heater Manufacturer
25 Years in Industrial Heating Elements | Cartridge Heater Specialist | OEM/ODM Manufacturer
- Swaged high-density construction for efficient heat transfer
- Precision diameter control for close bore fit
- Sheath materials matched to operating temperature and environment
- Electrical terminations matched to temperature and installation requirements
- Custom wattage distribution for different heat-loss profiles
High-Density Cartridge Heaters for High-Temperature Tooling
- Concentrated Heating in Limited Space The swaged construction provides the required heating output within a compact diameter, making it suitable for high-temperature metal tools with limited installation space.
- Shorter Heat-Transfer Path The resistance coil is positioned close to the outer sheath, shortening the path through which heat travels from the coil to the surrounding metal component.
- Reduced Heat Loss Use aerogel insulation and a stainless steel sheath to reduce heat loss to the surrounding air.
- Highly Compacted MgO Insulation The swaging process compacts the magnesium oxide around the resistance coil, providing both electrical insulation and effective heat conduction at elevated operating temperatures.
- Faster Tool Heating and Recovery When installed in a close-fitting bore, the heater transfers heat directly into the surrounding metal, helping the heated zone reach its set temperature and recover heat lost during operation.
- Reliable High-Temperature Operation Heat-resistant internal materials, compacted construction, suitable watt density, and correct bore fit work together to limit internal overheating and support stable heater performance.
What is a High-Density Cartridge Heater?
A high-density cartridge heater is a swaged cylindrical heating element designed for insertion into a close-fitting bore in a metal mold, die, platen, or heating block. Swaging compacts the magnesium oxide insulation and positions the resistance coil close to the sheath, shortening the heat-transfer path and allowing higher watt density when required by the application.
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JIEO can customise the diameter, heated length, wattage distribution, sheath material, thermocouple, and lead termination according to the bore dimensions, operating temperature, and thermal load of the heated component.
Types of JIEO High-Density Cartridge Heaters
Single-Ended Straight Termination with High-Density Cartridge Heater
Both lead wires exit straight from one end of the heater. Suitable when sufficient axial space is available for wiring.
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Double-Ended Straight Termination with High-Density Cartridge Heater
One lead wire exits from each end of the heater, allowing electrical connections to be routed from both sides of the heated component.
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Internal Lead Electric Termination with High-Density Cartridge Heater
Flexible lead wires are connected inside the heater and exit directly from one end. This provides greater flexibility close to the lead exit.
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External Pins with Leads Electric Termination with High-Density Cartridge Heater
Flexible lead wires are connected to solid terminal pins outside the heater, providing a reinforced transition between the heater and the wiring.
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Single-Ended Right-Angle Termination with High-Density Cartridge Heater
Both lead wires exit at 90 degrees from one end of the heater. Suitable where space behind the heater is limited.
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JIEO High-Density Cartridge Heaters Compaction and Precise Diameter Control
JIEO uses controlled multi-pass swaging to reduce a Ø10 mm tubular heating element to a finished diameter of Ø6 mm—a 40% reduction. This process uniformly compacts the magnesium oxide around the resistance coil, improving thermal conductivity and dielectric strength. This ensures faster heating, more even heating, reliable electrical insulation, and a longer heater service life.
Each heater is swaged to a precise, straight final diameter for a close fit in your mold’s mounting holes. The tighter fit minimises the air gap between the heater sheath and the mold, allowing heat to transfer more efficiently into your equipment. The heater can be installed more easily, heat up faster, provide more accurate temperature control, and reduce the risk of internal overheating.
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High-Density Cartridge Heaters with Configurable Wattage Distribution
JIEO offers five heat-distribution designs for high-density cartridge heaters to match how heat is absorbed and lost along the heater. Standard uniform wattage provides consistent output per unit length for parts with relatively even heat demand. End-compensated distributed wattage concentrates more output at both ends to offset faster edge heat loss and improve workpiece temperature uniformity.
Custom distributed wattage divides the heated length into predetermined high-, medium-, and low-wattage sections to match variations in part thickness and local thermal load. Custom no-heat sections omit active winding at specified positions to align with holes, slots, seals, sensors, or other areas where direct heating is unnecessary.
An extended cold section increases the unheated length at the lead end, reducing the thermal load on the lead connection, end seal, and nearby heat-sensitive components. These heat-distribution options provide a suitable temperature profile and stable heater performance to match your operating equipment.
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Description
Diameter Range
6 mm-28 mm (0.23”-1.1”)
Diameter Tolerance
± 0.02 mm
Length Range
50 mm-800 mm（1.96”-31.49”)
Length Tolerance
± 1 mm
Standard Clod Section
10 mm (0.39”) (customizable)
Voltages
380V, 240V, 220V, 110V, 36V, 24V or 12V
Operating Temperature
760°C
Resistance tolerance
+5% / -10%
Dielectric Withstand
1500 V/60 sec
Resistance wire
Ni80Cr20
Insulation
High-Purity Magnesium Oxide (MgO)
Sheath Materials
SS201，SS304，SS310S，SS316，TA1，Alloy 800
Material selection is subject to the operating temperature and environment.
Integrated Thermocouple
Type J or K; location customised
Certifications & Quality Assurance
JIEO high-density cartridge heaters are manufactured under an ISO 9001-certified quality management system and meet CE and RoHS requirements, helping you complete supplier qualification and compliance reviews with confidence.
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High-Density Cartridge Heater Applications for Industrial Tooling and Process Heating
Injection Mold Plates, Inserts, and Cores
JIEO high-density cartridge heaters can be inserted into drilled holes in mold plates, heated inserts, and cores where specific areas of the tooling require controlled heating. Each heater transfers heat directly to the metal surrounding its bore, while multiple heaters can be positioned across the tooling to cover the required heating zones.
Need a High-Density Cartridge Heater for Your Application?
Send the JIEO team your heater diameter and length, voltage, wattage, lead configuration, and application requirements.
Extrusion Die Bodies and Adapters
JIEO high-density cartridge heaters can be installed in drilled holes around extrusion die bodies, adapters, and melt channels where conductive heating is required. Each heater transfers heat to the surrounding metal along its bore, and multiple heaters can be arranged across wide or long tooling sections. Heated length, wattage, and heater position can be specified to suit edges, openings, or thicker areas with varying heat-loss conditions.
Need a High-Density Cartridge Heater for Your Application?
Send the JIEO team your heater diameter and length, voltage, wattage, lead configuration, and application requirements.
Meltblown Die Bodies
JIEO high-density cartridge heaters can be installed in parallel-drilled holes within meltblown die bodies where controlled heat is required along the polymer channel and nozzle row. Each heater transfers heat to its surrounding metal section, and multiple heaters are spaced across the die width to create separate heating zones. Heater length, active area, and spacing can be specified to achieve a more consistent temperature profile across the working width.
Need a High-Density Cartridge Heater for Your Application?
Send the JIEO team your heater diameter and length, voltage, wattage, lead configuration, and application requirements.
Rubber Molds and Vulcanising Platens
JIEO high-density cartridge heaters can be inserted into drilled holes in rubber mould plates, cavity blocks, inserts, or vulcanising platens where curing surfaces require controlled heat. Each heater supplies heat to the metal surrounding its bore, and multiple heaters are distributed according to mould thickness, cavity layout, and heat-loss areas. This allows heating capacity to be positioned where the tooling needs it across the curing surface.
Need a High-Density Cartridge Heater for Your Application?
Send the JIEO team your heater diameter and length, voltage, wattage, lead configuration, and application requirements.
Packaging Sealing Jaws and Bars
JIEO high-density cartridge heaters can be installed in bores within sealing jaws, sealing bars, and cutting-and-sealing tool holders where the working edge requires conductive heat. Each heater transfers heat into the surrounding metal, and multiple heaters can cover longer sealing sections. Heater position and wattage can be specified for the tool layout, with additional output near the ends where heat loss may be greater during repeated sealing cycles.
Need a High-Density Cartridge Heater for Your Application?
Send the JIEO team your heater diameter and length, voltage, wattage, lead configuration, and application requirements.
Heating Blocks, Hot-Knife Holders, and Custom Fixtures
JIEO high-density cartridge heaters can be inserted into cylindrical bores in heating blocks, hot-knife holders, forming tools, assembly fixtures, and test components requiring localised heat. Each heater transfers heat directly into the metal surrounding its bore, and the heated length can be aligned with the required working section. Custom cold sections can also avoid sensor holes, mounting slots, seals, or lead-exit areas that should receive less heat.
Need a High-Density Cartridge Heater for Your Application?
Send the JIEO team your heater diameter and length, voltage, wattage, lead configuration, and application requirements.
High-Density Cartridge Heater Factory & OEM Process
JIEO provides build-to-print OEM manufacturing for custom high-density cartridge heaters. Submit the finalised production drawings, electrical specifications, and quantities, and we will manufacture the heater set according to your requirements.
01
Submit Your Production Drawing
Send us the confirmed heater drawing, including dimensions, voltage, wattage, terminal positions, cable requirements, and order quantity.
02
Technical Review and Quotation
JIEO engineers review the drawing for manufacturing feasibility and check the dimensional and electrical specifications. If any information is missing or inconsistent, we will contact the customer for clarification before issuing the final quotation.
03
Order and Specification Confirmation
After the quotation is accepted, we confirm the order quantity, production drawing, electrical specifications, delivery requirements, and packaging instructions.
04
Manufacturing and Inspection
The heater set is manufactured in accordance with the confirmed drawing. Critical dimensions and agreed electrical parameters are checked before the order is released for packing.
05
Packing, Shipment, and Installation Support
The heater is wrapped in bubble wrap or foam padding and packed into cardboard or wooden boxes. Shipped by express, air, or sea.
Frequently Asked Questions
Ask JIEO EngineersAre high-density and high-watt-density cartridge heaters the same?
Not necessarily. High-density describes the swaged construction, which compacts the MgO insulation and shortens the heat-transfer path. High-watt-density describes the power applied per unit of heated surface area. One refers to construction; the other refers to surface power loading.
How do I select the correct high-density cartridge heater for a mold, die, or heating block?
You can provide a drawing or existing heater specification. JIEO engineer will match the heater construction to the heated component.
What hole fit and installation conditions are required?
Use a straight, clean bore with a single-side clearance of no more than 0.05 mm, equivalent to a total diametrical clearance of 0.10 mm. Excessive clearance reduces heat transfer and increases the heater’s operating temperature.
What affects the service life of a high-density cartridge heater?
Common causes of premature failure include excessive bore clearance, exposed operation, incorrect voltage, moisture, loose electrical connections, repeated lead bending, and excessive heat around the lead end. Correct installation and temperature control help extend service life.
Can JIEO reproduce an existing cartridge heater, and how is lead time confirmed?
Yes. Provide a confirmed drawing or physical sample. The typical production time is 7–15 days, excluding shipping time. Large orders can be produced and shipped in batches according to the confirmed production schedule.
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Discuss Your Heating Requirement
Share your application details, dimensions, electrical requirements, or drawings. JIEO team will review your request and recommend a suitable heating solution.