Achieving Repeatable Heat Control in Complex Aerospace Applications

Aerospace & Defense manufacturing is a system of precision: CAD files become mission-ready components through tightly controlled processes, each step dependent on the accuracy of the one before. When heat is unstable, when it ramps unpredictably or drifts across the mold, it affects not just that step, but the entire chain of performance and quality downstream.

The Watt-Flex® cartridge heater was developed to stabilize that foundation. By engineering consistent bore contact and uniform thermal transfer, it eliminates common heat-related variables, putting process control in your hands.

Why Traditional Cartridge Heaters Fall Short

Standard cartridge heaters are often ill-suited for the thermal demands of aerospace and defense applications. Over time, these heaters shrink or seize inside the bore, leading to poor surface contact and the development of temperature gradients. These hot and cold zones compromise not only the thermal profile but also the structural and dimensional integrity of the parts being produced.

These inconsistencies can manifest as:

• Warping and internal stresses in cured composites
• Localized under-curing or overheating
• Premature grain growth in high-temperature forming
• Delaminations, porosity, or shrinkage defects
• Reduced repeatability and throughput

In mission-critical sectors like aerospace, where tight tolerances and material properties must be exact, these risks are simply unacceptable.

Watt-Flex®: Precision Where It Counts

Watt-Flex® split sheath technology directly addresses the core issues that plague conventional heating methods. Its dual-sheath design expands outward when energized, ensuring full radial contact with the bore wall and eliminates air gaps, even as the heater thermally cycles.

This expansion-contraction behavior delivers three critical advantages:

Uniform Heat Transfer
The expanding sheath guarantees even thermal conduction across the entire length and surface of the heater, eliminating temperature gradients and ensuring stable heat input, corner to corner, cavity to cavity.

Process Control and Repeatability
With more responsive heating and consistent bore contact, engineers can tightly control ramp-up, hold, and cooldown phases without overshoot. This leads to improved part consistency and fewer thermal-induced defects.

Faster, Cleaner Operation
Because the heater contracts upon cooldown, removal is easy and damage-free. There’s no need for bore cleaning or tool modification, which means less downtime and lower maintenance overhead.

Application-Specific Benefits for Aerospace & Defense

In Resin Transfer Molding (RTM) and Thermoset Curing:

• Watt-Flex stabilizes resin flow and crosslinking by providing consistent cure profiles.
• It reduces scrap and rework due to warpage, voids, and cure distortion.
• Aerospace-grade composites benefit from the precise thermal control necessary to meet FAA and DoD certification standards.

In Superplastic Forming (SPF):

• Uniform heat input supports the consistent strain rates needed for elongation.
• Microstructural integrity is preserved by preventing thermal gradients that lead to premature grain growth.
• The risk of wrinkling, thinning, and cavitation is reduced, resulting in higher-quality structural components with fewer forming anomalies.

Driving Better Outcomes: Throughput, Quality, and Cost

By delivering stable, responsive, and uniform heat, Watt-Flex® helps manufacturers:

• Accelerate cycle times without sacrificing part integrity
• Improve tool life by reducing thermal fatigue and removal damage
• Lower energy loss by improving heat transfer efficiency
• Achieve more predictable, repeatable outcomes, critical in regulated sectors like aerospace and defense

In essence, Watt-Flex doesn’t just heat your tooling, it enhances your entire process.

See the Difference for Yourself

If your team is struggling with cure variability, dimensional drift, or forming inconsistencies, it may not be your mold, it may be your heater.

At Dalton Electric, we’ve spent decades engineering cartridge heaters that don’t just meet specs, they redefine expectations. Let’s talk about how Watt-Flex® can optimize your thermal processes and improve your operational outcomes.