Silicone Rubber Heaters
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From initial concept to final production, Durex partners closely with customers to ensure every silicone heater meets precise specifications.
Silicone Rubber Heater Key Design Features:
- Custom flexible configurations
- High dielectric strength and fatigue resistance
- Resistant to ozone, weather, and chemicals
- Flame retardant and non-toxic
- Low outgassing—free from sulfur and nitrogen compounds found in organic rubbers
- Proven thermal stability for demanding applications
Silicone Rubber Heaters - Alternative to Metallic Heaters
Silicone rubber heating elements offer a lightweight, high-efficiency alternative to traditional rigid metal heaters. Designed for versatility, they can be applied using various methods depending on equipment needs:
- Clamped between metal plates (with or without insulation)
- Bonded to metal surfaces using Pressure Sensitive Adhesive (PSA)
- Vacuum bonded (vulcanized) to form heated components
- Mechanically secured with straps, springs, or other fasteners
How Silicone Rubber Heating Elements Are Made
Etched Foil Elements
Using a Durex-engineered photo tool, we develop and chemically etch a precision resistive foil circuit, which is then vulcanized within the silicone heater.
Key advantages:
- High coverage (>50%) for lower internal element temperature and extended heater life
- Superior performance at high watt densities and elevated temperatures
- Custom watt distribution by varying circuit trace width
- Cost-effective for high-volume, small-size production
Durex manufactures wire wound heaters using computer-designed winding patterns and dedicated tooling. Resistance wires can be combined or stranded for optimal performance, often wound around a fiberglass core for added strength and flexibility.
Key advantages:
- Best suited for large heaters, low watt densities, and small production runs
- Supports parallel redundant circuits for critical applications
Partner with Durex Industries for Your Custom Silicone Heater Solutions
At Durex Industries, we specialize in delivering custom silicone rubber flexible heaters designed to meet your unique application needs. Our expert engineering team works with you from initial concept through final production, ensuring a seamless and collaborative experience every step of the way.
With advanced design capabilities and a commitment to quality, our heaters provide reliable performance that transforms your ideas into reality.Ready to get started?
Contact our engineering team today to develop a heater solution tailored to your application, from concept through production.
Durex Industries—your trusted partner in silicone rubber heater manufacturing.
Silicone Rubber Heaters Specs & Options
Back to TopDurex offers flexible heating element component recognition for both UL and Canada under UL File No. E110394. We continually expand our product offerings under component recognition—please contact Durex for the latest inclusions.
Our engineering team can also assist OEMs in achieving UL listing for equipment incorporating heating elements. With extensive experience resolving certification challenges, Durex provides valuable support throughout the approval process.
- Sizes: Up to 36" wide (consult factory for custom dimensions)
- Standard Thickness: 0.030", 0.043", 0.056"
- Operating Temperature:
- Maximum: 400°F (204°C) intermittent
- Minimum: -60°F (-50°C)
- Maximum Watt Density: 60 W/in²
- Maximum Voltage: 600 VAC
- Wattage Tolerance: Standard +5% / -10%
Heater Wattage & Voltage Options
Wattage
Durex manufactures silicone rubber heaters with a wide range of wattage and power configurations. While uniform watt density (watts per square inch) is standard, our engineering team can design custom power profiles to concentrate heat where it’s most needed.
For example, when heating a plate, the perimeter can be configured with higher watt density to minimize edge heat loss and maintain uniform surface temperature.
We also offer independent circuit designs that allow two different power densities within the same heater. A common approach uses a high-power circuit for rapid heat-up and a low-power circuit for energy-efficient temperature maintenance—ideal for battery-powered applications where conserving power is critical.
Durex silicone rubber heaters support voltages up to 600 VAC/DC. For high-voltage applications, we select materials and design elements to meet stringent dielectric requirements.
Dual-voltage heaters are also available. A typical configuration is 120/240 VAC, using a three-wire lead arrangement so OEMs can stock a single heater for both voltage systems. This is achieved by designing two circuits that can be wired in series or parallel to deliver consistent wattage output.
For specialized applications, such as aerospace and aviation, Durex provides 28/120 VAC heaters with independent circuits to maintain identical wattage performance under either voltage.
Silicone Heater Attachment Methods
Durex offers multiple attachment options for silicone rubber heaters, tailored to application requirements such as watt density, operating temperature, part geometry, and substrate material.
During the heater manufacturing process, Durex can vulcanize the heating element directly to the customer’s part. This method provides superior heat transfer through an intimate, uniform bond and reduces assembly time for faster production. Proprietary vulcanization techniques accommodate a wide range of part geometries.
Heaters can be supplied with PSA backing and a removable liner for easy installation. Depending on substrate and temperature requirements, Durex selects either acrylic-based or silicone-based adhesives for optimal performance. Surfaces must be clean and free of oil or grease prior to application.
Room Temperature Vulcanizing (RTV) silicone offers a high-strength bond suitable for high-temperature environments. For large heaters, two-part RTV may be required since one-part RTV relies on humidity for curing. Consult Durex for installation guidance.
For applications requiring frequent removal, Durex provides a variety of fastening options, including:
- Grommets for lacing
- Grommets with springs or buckles
- Velcro®
- Nylon or silicone straps with “D” rings
- Straps with ITW Nexus-style two-part buckles
Thermostats
Heaters can be equipped with thermostats for over-temperature protection or basic temperature regulation where tight precision is not required. Placement determines functionality:
- Over-heated section: Limits heater temperature to a maximum threshold.
- Non-heated section: Monitors part temperature for indirect control.
For precise electronic control, heaters can incorporate sensors such as RTDs, thermistors, or thermocouples. These can be positioned over heated or non-heated sections to monitor either heater or part temperature. As a manufacturer of both heaters and sensors, Durex offers unmatched expertise in designing complete thermal systems.
Single-use thermal fuses provide a fail-safe shutdown in critical applications if primary or secondary controls fail. Placement can be overheated or non-heated sections. Industry standards recommend a 100°F differential between the primary control setting and fuse activation to prevent nuisance tripping.
Durex offers multiple lead wire configurations, including Teflon®-insulated stranded wire, silicone wire, and cord types such as HPN or SJO. Heaters can be supplied with sleeved individual leads or integrated connectors—from simple terminals to complex multi-pin assemblies for multi-zone heaters and sensors. This flexibility reduces part numbers and accelerates production.
To improve efficiency and reduce surface temperature, heaters can be paired with insulation materials. Common options include silicone sponge (⅛" to ½") for silicone heaters and engineered insulations for polyimide heaters, tailored to environmental requirements.
Request a quote or contact Durex engineering for assistance in selecting the right construction for your application.
Silicone Rubber Heaters Typical Applications
Back to TopCommon applications include:
- Battery warming
- Freeze protection
- Autoclaves
- Drum heaters
- Incubators
- Liquid reservoirs
- Optical equipment
- Packaging machinery
- Refrigeration equipment
- Security devices
- Vacuum chambers
Contact our engineering team today to develop a heater solution tailored to your application, from concept through production.