Soloheat Cast Aluminium & Aluminium Bronze Industrial Heating Elements
Soloheat specializes in the custom design and manufacture of high-performance Cast Aluminium and Cast Aluminium Bronze heaters. Operating from our facility in Gloucestershire, we are proud to be the only foundry in England dedicated exclusively to manufacturing Cast Alloy Industrial Heating Elements for a global market.
Engineered for exceptional durability, uniform heat distribution, and extended operational lifespans, our cast alloy heaters are built to withstand heavy-duty industrial processing environments without compromising on performance.
Key Technical Capabilities
When your machinery requires maximum reliability and precise thermal control, our bespoke cast-in elements provide superior power density compared to standard band heaters.
- Extreme Temperature Resistance: High-temperature thresholds available up to >600°C (1112°F), with recommended application starting from >300°C (572°F).
- Custom Dimensional Freedom:
- Round Heaters: Minimum ID of 10mm up to a maximum ID of 800mm. Custom widths from 20mm to 800mm.
- Flat / Platen Heaters: Minimum length of 60mm and minimum width of 20mm.
- Minimum Profile Thickness: Starting from 16mm (subject to dimensional configurations).
- Optimized Power Densities:
- Cast Aluminium: Up to <40 watts/inch² (6.2 W/cm2) at 400°C.
- Cast Aluminium Bronze: Up to <50 watts/inch² (7.75
- W/cm2) at 550°C.
Bespoke Assembly & Production Efficiencies
At Soloheat, we do not just manufacture standard replacement parts—we actively engineer thermal solutions designed to optimize your workflow. By casting and fitting bespoke elements directly to our customers’ specific components and tooling, we eliminate complex installation steps, reduce downtime, and facilitate streamlined machinery assembly.
Whether integrated into precision molds or complex industrial manifolds, our custom-fit heating elements are engineered to enhance your overall production efficiency and ensure absolute thermal uniformity across the entire tool surface.
Typical Applications & Core Industries
Our robust cast-in heating elements are globally specified across high-stakes engineering sectors requiring strict adherence to tight tolerances. They are ideally suited for:
- Aerospace Engineering: Specialized heating elements tailored for composite curing, tool heating, and components required for rigorous aerospace manufacturing standards.
- Petrochemical Processing: High-durability, cast-in thermal solutions built to withstand corrosive environments and demanding fluid-handling applications.
- Plastics & Extrusion: Extrusion and injection moulding barrels, transfer pipes, and fluid processing lines.
- Packaging Machinery: Extrusion die blocks, heated platens, packaging machinery jaws, and heat-sealing tools.
Specialized Variations: Air & Water Cooled Units
Air-Cooled Cast Aluminium & aluminium bronze Finned Heaters
Designed primarily for extruder barrels requiring highly accurate temperature control. These feature custom-cast internal or external fins engineered to work alongside centrifugal fans. Soloheat can manufacture the complete assembly, including custom cowls, shrouds, and ducting to integrate seamlessly with your machinery.
Water-Cooled Cast Alloy Heater Coolers
For processes requiring liquid cooling to maintain strict thermal limits. We cast heavy-duty stainless steel or Incoloy cooling tubes (available in 3/8”, 1/2”, and 1” outer diameters) directly alongside the electric heating element. This ensures rapid heat dissipation and prevents internal thermal stress during rapid heating and cooling cycles.
Custom Terminations, Patterns & Dies
Every heater is terminated to match your exact environmental and machine requirements. Options include IP65 dust and moisture-proof housings, standard 2 or 3-pin plugs, terminal boxes, block terminals, screw terminals, or flexible metal braided or conduit armoured leads.
Reduced Tooling Costs: Soloheat holds a vast archive of existing patterns and dies. Our in-house pattern-making shop (both woodworking and 3D printing) and fabrication shop (dies) can rapidly modify existing tooling or work directly from your physical machinery samples to dramatically minimize new pattern costs.
Request a Quote & Specification
Global Lead Times: 2–3 weeks for standard cast items | 4–6 weeks* for complex, bespoke units.
Need a direct replacement, a custom build, or a tailored element fitted to your custom tooling? Contact our technical design team today at sales@soloheat.co.uk or call us +44 (0)1453 752459 to discuss your project requirements.
*subject to quotation
Click here to download our Cast Heater survey sheet template
FAQ answers:
- Potential power density greater than other types of band heater.
- Highest application temperatures available > 600oC / 1112oF
- Recommended application temperatures > 300oC / 572oF
- Round heater Minimum / Maximum diameter = 10mm id / 800mm id
- Round heater Minimum / Maximum width: 20mm / 800mm
- Flat heater minimum length = 60mm
- Flat heater minimum width = 20mm
- Minimum heater thickness = 16mm (dependant upon other dimensions)
- Maximum Power densities:
- Aluminium heaters <40 watts / inch² (6.2w/cm²) – 400 Degrees Celsius
- Aluminium bronze heaters <50w/inch² (7.75w/cm²) – 550 Degrees Celsius
