Aerospace & Defense

Challenge

An advanced composites manufacturer, supplying next-generation turbine components, faced mounting pressure on its Resin Transfer Molding (RTM) process. Production was slowed by scrap waste, inconsistent cure quality, and unexpected downtime, all of which jeopardized throughput and structural reliability.

The complexity of oversized composite molds compounded the challenge. Conventional cartridge heaters struggled to provide uniform heat, causing cure variability, part defects, and tooling stress. Meeting aggressive aerospace production schedules demanded a heating solution that could deliver precision, durability, and reliability under pressure.

Solution

Dalton Electric partnered closely with the manufacturer's engineering team to design a custom Watt-Flex® split-sheath cartridge heating system engineered specifically for aerospace-grade RTM applications.

The solution provided:

• Full contact, uniform heating across oversized composite molds.
• Fast cycle recovery times to keep production schedules on track and reduce scrap.
• Exceptional durability, withstanding repeated cycles without failure.
• Consistent thermal profiles, minimizing cure variability and improving part quality.
• Faster ramp-up and cycle times, enabling throughput goals to be met with confidence.

Maximize Heat Transfer

Watt-Flex Cartridge Heaters offer a unique split-sheath design that enables independent, bilateral expansion of each half of the heater outward against the walls of the surrounding bore. This innovative design provides exceptional benefits for customers:

Superior Heat Transfer: The close contact between the heater and the bore ensures efficient heat transfer, maximizing the effectiveness of your heating process.

More Uniform Process Heat: The consistent heat transfer across the entire length of the heater minimizes temperature variations, resulting in more uniform process heat distribution.

Greater Efficiency: Improved heat transfer translates to reduced energy consumption, lowering your operating costs and environmental impact.

Reduced Electricity Consumption: By maximizing heat transfer and efficiency, Watt-Flex Cartridge Heaters minimize the amount of electricity required to achieve your desired heating goals.

Effective Heating in Oversized Bores: Even if your bores are oversized due to previous use or drill-outs, the bilateral sheath expansion of Watt-Flex Cartridge Heaters ensures maximum contact for optimal conduction heating.

Unmatched Performance for Your Heating Applications

Watt-Flex Cartridge Heaters are the ideal solution for a wide range of heating applications, delivering unmatched performance and significant cost savings. Their unique split-sheath design and superior heat transfer capabilities make them the preferred choice for industries that demand the highest standards in efficiency and effectiveness.

Invest in Watt-Flex Cartridge Heaters and experience the difference:

Reduced Energy Costs: Lower your electricity consumption and minimize your carbon footprint.

Enhanced Process Quality: Enjoy more uniform process heat distribution for consistent results.

Extended Heater Lifespan: Benefit from improved heat transfer and reduced thermal stress, leading to longer heater life.

Simplified Maintenance: Eliminate bore seizure and avoid costly drill-outs.

Peace of Mind: Enjoy the confidence of using industry-leading cartridge heaters backed by a reputable manufacturer.

Embrace the future of efficient and effective heating with Watt-Flex Cartridge Heaters. Contact us today to discuss your specific application requirements and discover how Watt-Flex can elevate your heating processes to new heights.