JLCPCB Flexible Heater Manufacturing Process: A Comprehensive Guide

In various industries, resistive heating elements play a critical role in converting electrical energy into heat. As demand grows for more compact and customizable thermal solutions, flexible heater manufacturing has become essential to producing efficient and reliable heating components. Flexible heaters, particularly polyimide (PI) flexible heaters, are known for their thin, lightweight, and adaptable design, which is crucial for effective thermal management across a wide range of applications—from consumer electronics to aerospace systems. JLCPCB Flexible Heater offers specialized design and manufacturing services for polyimide heating films, delivering high-performance heating solutions tailored to meet specific requirements.

Why Polyimide Flexible Heaters?

Before diving into production, it’s worth understanding why polyimide-based flexible heaters are the go-to choice for demanding thermal applications. Their exceptional thermal stability (operating reliably from -200°C to over 250°C), chemical resistance, and mechanical flexibility make them ideal for tight spaces and dynamic environments. Unlike rigid alternatives, PI heaters conform to curved surfaces without compromising performance—enabling smarter thermal integration in wearables, medical devices, battery systems, and more. JLCPCB leverages these material advantages while combining them with rigorous process control to ensure consistency from prototype to volume production.

JLCPCB Polyimide Flexible Heater Manufacturing Process

1. Design & Substrate Preparation

Design File Submission

To begin the process, provide JLCPCB with essential details such as voltage, power/resistance, and size (L×W). Based on this information, JLCPCB's team offers free circuit design tailored to your requirements.

Material Cutting

The flexible heater substrate, which can be made from brass, stainless steel, or FeCrAl, is cut precisely to the required size and shape using advanced cutting equipment.

2. Circuit Patterning via Photolithography

Dry Film Coating

A dry film, crucial for the final quality and performance of the heater, is applied to the metal substrate in a cleanroom environment, ensuring optimal surface adhesion.

Exposure

A dual-stage direct imaging system uses laser exposure to harden the areas of the circuit pattern, accurately transferring the design onto the dry film.

Development

The exposed substrate undergoes a development process, where unexposed dry film is dissolved to reveal the precise circuit pattern. The hardened areas remain intact, resisting etching.

Etching and Stripping

Etching removes the unwanted parts of the substrate, leaving behind the resistive circuit traces. The dry film layer is then stripped away, exposing the final circuit pattern.

3. Lamination & Structural Integration

Cover Film Cutting

The polyimide cover film is cut precisely to the required dimensions using a cutting machine, preparing it for the insulation of the circuitry and the final heater shaping.

Film Hole Punching

UV laser punching creates holes in the cover film to allow for component connections and alignment during subsequent processes.

Film and Substrate Alignment

The cover film is carefully aligned with the etched substrate. Precise alignment of holes and pads ensures a seamless connection and stable heating performance.

High-Temperature Laminating

Using a high-temperature laminating machine, JLCPCB applies heat and pressure to bond the cover film to the substrate, creating a durable heater structure. This step enhances the heater's lifespan and stability.

Oven Curing

After lamination, the custom heater undergoes a gentle curing process in an oven. This step enhances material stability and durability, ensuring long-term performance.

Double-Sided Adhesive Application

3M double-sided adhesive is applied to the heating film at specific points, allowing easy and secure attachment to the final product during installation.

Shaping and Cutting

The flexible heater is die-cut into its final shape based on the design specifications of the end product, ensuring the perfect fit.

4. Electrical Integration & Final Validation

Solder Pad Tin Coating & NTC Temperature Control Welding

Customers can specify the need for soldering pads, NTC temperature sensors, and temperature control features during the order process, with precise welding to ensure reliable operation.

Solder Leads and Glue for Solder Pads

JLCPCB Flexible Heater offers flexible leads in various lengths and diameters, along with different packaging options, ensuring customization based on client requirements.

Cleaning Solder Points

Excess solder and impurities around the soldering points are cleaned to improve the overall cleanliness, reliability, and long-term stability of the product.

Silicone Sealing

Silicone sealing is applied around the edges of the heating film for insulation, water resistance, and to enhance pad stability, providing additional protection.

100% Resistance Testing

Finally, each unit undergoes manual resistance testing to ensure consistency within a ±5% tolerance, ensuring high-quality performance across all units.

Quality Assurance and Real-World Reliability

While the 18-step process outlines how JLCPCB builds each heater, what truly sets the service apart is the integration of quality checks at every phase—not just at the end. From cleanroom coating to laser-precision alignment and final electrical validation, each stage is monitored to prevent drift or defect. This end-to-end control translates into heaters that perform reliably under real-world stress: thermal cycling, vibration, humidity, and repeated flexing. For engineers, this means fewer redesigns, faster validation, and confidence in thermal performance from day one.

Conclusion

Understanding each stage of the polyimide flexible heater manufacturing process provides clarity on how these components achieve stable performance in demanding environments. From material preparation to final inspection, each step depends on precise control and consistent quality.

If you’re evaluating thermal solutions for your next project, exploring a manufacturer that follows such rigorous processes can make a significant difference. JLCPCB’s flexible heater service applies these standards across every production run, making it easier for engineers to move from prototype to reliable end-use performance.

Current Discounts from JLCPCB:

• Polyimide Flexible Heater (≤150×150 mm, 3 pcs) – Only $1

• Silicone Rubber Heater (≤150×150 mm, 3 pcs) – Only $3

• These prices apply to orders matching the exact specs above—don’t miss this rare opportunity!