Hi-Temp Cartridge Heaters
High Watt Density Heating for Precision Insert Applications
TUTCO’s Hi-Temp Cartridge Heaters are engineered to deliver high-performance, high watt density heating in precision insert applications where fast heat transfer and reliable operation are critical. Designed for insertion into drilled holes, these heaters provide direct conductive heat to solid materials, making them ideal for tooling, dies, platens, and industrial equipment. With heat transfer rates up to 100 W/in² and continuous operating temperatures up to 1200°F (649°C) (1400°F intermittent), Hi-Temp Cartridge Heaters are built to handle demanding industrial environments and high-output processes. Manufactured in the USA and fully customizable, TUTCO’s Hi-Temp Cartridge Heaters provide a reliable, high-efficiency solution for OEM and industrial heating applications.
How Hi-Temp Cartridge Heaters Work
Hi-Temp Cartridge Heaters are designed for conductive heat transfer, where the heater is inserted into a precisely sized hole in a metal component. When energized:
- Electrical current flows through a nickel-chromium resistance element
- Heat is generated within the heater
- High-purity magnesium oxide (MgO) transfers heat to the sheath
- Heat conducts directly into the surrounding material
The swaged construction compresses internal components, minimizing air gaps and improving heat transfer efficiency. This design also increases durability and resistance to vibration and mechanical stress. Because conduction is the most efficient form of heat transfer, proper fit between the heater and the hole is critical to performance and longevity.
| Specifications | |
| Maximum Watt Density | 100 Watts/sq. in |
| Maximum Sheath Temperature | 1200°F continuous, 1400°F intermittent |
| Sheath | Incoloy 800 |
| Wattage Tolerance | +5%/– 10%, based on NEMA standards |
| Resistance Tolerance | +10%/–5% 3.3% lower at room temperature |
| Standard Voltages | 120V, 240V. Others available upon request |
Features and Benefits
High Watt Density Performance
Capable of delivering up to 100 W/in², enabling rapid heat-up and high-output process capability.
High-Temperature Operation
Designed to operate continuously up to 1200°F (649°C) and intermittently up to 1400°F (760°C).
Superior Heat Transfer
Efficiency Swaged construction minimizes internal air gaps, maximizing thermal conductivity and efficiency.
Rugged, Durable Design
Engineered to withstand Impact and vibration, thermal cycling, and harsh industrial conditions.
Wide Range of Sizes and Configurations
Available in a broad range of diameters, lengths, voltages, and wattages to suit virtually any application.
Flexible Electrical Options
Standard voltages (120V, 240V) with custom options available.
Dual voltage and three-phase configurations on select designs.
Extensive Customization Options
Hi-Temp Cartridge Heaters can be customized with:
- Internal thermocouples
- Flanges, bushings, and mounting features
- Distributed wattage and zoning
- No-heat sections
- Lead wire protection (braid, armor)
- Sealed terminations for moisture resistance
Design Considerations
Selecting the right Hi-Temp Cartridge Heater requires evaluating:
- Hole size and fit (critical for heat transfer)
- Operating temperature and watt density
- Material being heated
- Environmental conditions (moisture, vibration, contamination)
- Electrical requirements and control systems
Proper fit is essential. Cartridge heaters are typically slightly undersized to fit into drilled holes, ensuring efficient insertion and heat transfer.
Resources
Applications
Hi-Temp Cartridge Heaters are designed for applications requiring high watt density, precision heating, and efficient heat transfer.
Plastics
Plastic processing applications rely on consistent, high-temperature heating for material flow and product quality.
- Compression molding
- Blown film processes
- Blow molding machines
- Plastic pellet drying
Packaging and Printing
Packaging systems require precise, repeatable heat for forming and sealing operations.
- Platen heaters
- Packaging and sealing bars
- Form-fill-seal packaging machines
- 3D printers
- Laminating applications
Processes
Industrial processes demand reliable heating for a wide range of applications.
- Textile processing
- Chemical processing
- Plastic pipe cutting / joining
- Glass processing
- Plastic pipe cutting/joining
- Scientific testing equipment
Food Service
Food-related applications require consistent and controlled heating.
- Food grade sealing and wrapping
- Food service warming
- Refrigeration systems
Transportation
Heating solutions support reliability and performance in transportation systems.
- Automotive applications
- Space heaters for public transport
- Agriculture transportation
- RV water heaters
- Battery warmers
Additional applications include holding tanks, drum and barrel heating, deicing and defrosting applications, enclosure heating, and cryogenic applications. If you have a special application, TUTCO offers a wide range of customization options to tailor the heater to your exact requirements.
Why Choose a Hi-Temp Cartridge Heater
High Performance and Reliability
Engineered for demanding applications requiring precision and durability.
Superior Heat Transfer
Swaged construction ensures efficient and consistent heating.
Extensive Customization
One of the most customizable heater solutions available.
Proven Industrial Performance
Trusted across plastics, packaging, and industrial processes.
Global Manufacturing Footprint
Flexible production capabilities support customers worldwide.
When to Choose Hi-Temp Cartridge Heaters
Hi-Temp Cartridge Heaters are the preferred solution when applications require high heat output, fast response, and precise localized heating.
Choose Hi-Temp Cartridge Heaters when:
- High watt density is required
- Fast heat-up and response are critical
- Heat must be applied inside a solid material
- The application involves vibration or demanding conditions
- Precise temperature control is needed
For lower temperature or less demanding applications, standard cartridge heaters may be appropriate.
Performance Considerations
Heat Transfer Efficiency
Proper hole fit and contact maximize conductive heat transfer.
Watt Density Management
Higher watt densities enable performance but must match application limits.
Thermal Cycling
Swaged construction improves durability under repeated heating cycles.
Application Impact
Heater performance must be balanced with the material and process being heated.
OEM Integration and Customization
Hi-Temp Cartridge Heaters are widely used in OEM equipment due to their precision, flexibility, and scalability.
TUTCO works with OEMs to develop solutions that:
- Integrate into tooling, dies, and machinery
- Meet high-performance thermal requirements
- Scale from prototype to production
- Support custom configurations and controls
Cartridges can be modified to meet the demands of special applications. Our engineers can utilize a variety of alternative features and options to customize the heater to your specific needs. Common customizations include:
- Internal Thermocouples
- Flanges, Top Rings, Tabs
- Brass or Stainless Steel Threaded Bushings
- Special Seals of Epoxy, RTV, Teflon
- Leadwire Protection, Stainless Steel Braid
- Leadwire Protection, Stainless Steel Armor
- Distributed Wattage
- No-Heat Sections
- Three Phase Construction
- Dual Voltage
- Zoned Heaters
- Square Cartridge Heaters
Learn more about customizing cartridge heaters in Ian Renwick’s white paper.
FLEXIBLE LEADS
Internally connected leads. For applications requiring maximum flexibility at lead exit. 10” (25.4 cm) leads standard, other lengths are available.
EXTERNALLY CONNECTED LEADS
Hi-Temp Cartridges are provided with approx. 1” (25.4 mm) sleeving over lead junction as standard. 10” (25.4 cm) leads standard, other lengths are available.
STRAIGHT LEADS WITH CLIP SUPPORT
Clip support helps to minimize lead breakage where leads exit heater. 10” (25.4 cm) leads standard, other lengths are available.
90° LEADS
Leads exit at 90° angle for applications where space is limited. 10” (25.4 cm) leads standard, other lengths are available. Order heater by overall length.
90° LEADS WITH CLIP
Clip support helps to minimize lead breakage where leads exit heater. 10” (25.4 cm) leads standard, other lengths are available.
STAINLESS STEEL BRAID
Stainless steel braid over lead wires. For applications requiring small radius bending and lead wire abrasion protection. 10" (25.4 cm) braid standard, other lengths are available.
STAINLESS STEEL ARMOR
Straight stainless steel armor cable protects leads from abrasion. Sizes include: 1/4", 5/16", 1/2", and 5/8". 10" (25.4 cm) standard, other lengths are available.
RIGHT ANGLE ELBOW
Right Angle Elbow Right angle copper elbow for applications requiring right angle lead exit. Moisture-resistant seal is optional. 10" (25.4 cm) leads standard, other lengths are available.
STRAIGHT STRAIN RELIEF SPRING
Straight strain relief spring minimizes bending strain on lead wires. Spring extends approximately 3" (76.2 mm) beyond end of sheath.
NPT BUSHING
Hex head N.P.T. bushing attached. Must specify insert length and bushing material. Sheath material types: stainless steel, cold rolled or galvanized. Bushing material types: brass or stainless steel. Octagonal box available.
HEX CENTER BUSHING
Hex head N.P.T. bushing attached. Must specify insert length and bushing material. Sheath material types: stainless steel, steel or brass. Bushing material types: brass and stainless steel. Octagonal or explosion-proof boxes can be adapted to both Standard and Hi-Temp Cartridge heaters.
ADAPTER
Must specify insert length and bushing material. Sheath material types: stainless steel, cold rolled or galvanized. Bushing material types: stainless steel.
ADAPTER WITH HEX HEAD
Must specify insert length. Bushing material is copper.
BOTTOM GROUNDED
For fast response, heater is positioned in a blind hole or where material flows past or encompasses the heater. The end disk is always welded in place. Machined flat up to 1/2″ (12.7 mm) dia.
BOTTOM UNGROUNDED
Where circumstances are such that an ungrounded thermocouple is required.
CENTER GROUNDED
Selected when a fast response is required. The thermocouple can be located in any position along the length of the heater. Standard location is midway along the length with approximately 1/4″ (6.4 mm) cold section on either side of the junction. Not available on 1/4” diameter heaters.
CENTER UNGROUNDED
The thermocouple is positioned internally and ungrounded to monitor the heater temperature. Generally used in research and development applications.
Thermocouple Availability
All heaters shown are Hi-Temp with type “J” thermocouple standard. Type “K” thermocouples are available. For standard Cartridge heaters thermocouples are available located at the bottom or center, ungrounded only.
ARMOR WITH PLUG
Armor cable with power plug attached. Must specify armor length and Hubbell ® power plug number. Moisture-resistant armor available. Other Plugs are available. Also available with Hex Head NPT bushing and armor.
BOLT HEATER
Bolt heaters are designed to heat drilled metal surfaces quickly while minimizing heat loss to surrounding areas. Each is designed to expand drilled bolts or studs while maintaining a uniform heat throughout its heated length. Typically, after a bolt is heated (expanded) the holding nut is tightened. The shrink tightness is obtained when the heater is removed and the bolt cools. This process is frequently used in the assembly and/or servicing of heavy duty equipment such as compressors, steam turbines, pressure vessels, etc.
Get Started with Hi-Temp Cartridge Heater Solutions
Share your application details and discover how TUTCO’s Hi-Temp Cartridge Heaters can improve performance, efficiency, and reliability across your process.
Contact our engineering team today to develop a custom heating solution built for your application.
Heater Leadwire Failure & How To Reduce Its Occurence
3D Printing Technology Requires Specific Heaters And Sensors
Heater Types Compared | Band, Strip, Cartridge & More
Preventing Heater FailureFrequently Asked Questions
Standard cartridge heaters are designed for dry, enclosed applications. Exposure to moisture or liquids can damage the insulation or cause electrical shorts. If your process involves liquid contact, TUTCO offers sealed or specialized designs that can withstand those conditions safely.
Lead wires and terminations aren’t just an afterthought—they can make or break heater performance. Properly rated and protected leads prevent electrical shorts, wear, or failure from vibration or high temperatures. Options like braided stainless steel leads or strain-relief fittings help heaters survive tough industrial environments while maintaining reliable electrical connections.
Yes — as long as the heater’s sheath material and termination are appropriate for your environment. Stainless steel sheaths, for example, resist corrosion and contamination, making them suitable for food-processing equipment. For sensitive electronics, the heaters provide localized heating with minimal stray heat, but you should always consider insulation and safety controls to prevent accidental contact or overheating.
Cartridge heaters are ideal when you need precise, localized heat in a compact space. If you’re heating molds, dies, or small metal blocks—or any setup where you can insert a cylindrical heater—they provide efficient, uniform heat. They’re especially useful for applications requiring high temperatures in a small footprint, like plastics processing, packaging, or lab equipment.
