Coil Heater Series Comparison & Selection Guide
This coil heater series comparison helps you select the right heating configuration for hot runner nozzles, injection molds and precision heating applications. Different coil heater cross-sections provide different levels of flexibility, contact area, watt density and installation precision.
EaseWise supplies five main configurations: Round, Square, Flat / Rectangular, Micro Mini and Pressed-in Brass. The right choice depends on nozzle size, available installation space, heating requirements, contact conditions and production requirements.
Coil Heater Series Comparison
| Item | Round | Square | Flat / Rectangular | Micro Mini | Pressed-in Brass |
|---|---|---|---|---|---|
| Cross-section | Φ3.0 / Φ4.0 / Φ5.0 mm | 3.0×3.0 / 3.3×3.3 / 3.5×3.5 / 4.0×4.0 mm | 2.2×4.2 / 4.0×2.0 / 4.5×2.7 mm | Φ1.8 / 1.3×2.3 mm | Based on inner coil configuration |
| Heating Length | 25–220 mm | 25–200 mm | 20–180 mm | 20–150 mm | 25–200 mm |
| Wattage | 100–1200 W | 120–1300 W | 100–1100 W | 80–600 W | 150–1500 W |
| Voltage | 110V / 220V; custom 24–240V | 110V / 220V; custom 24–240V | 110V / 220V; custom 24–240V | 110V / 220V; custom 24–240V | 110V / 220V; custom 24–240V |
| Inner Diameter Tolerance | ±0.20 mm | ±0.20 mm | ±0.15 mm | ±0.15 mm | ±0.08 mm |
| Minimum Bending Radius | ≥12 mm | ≥10 mm | ≥8 mm | ≥6 mm | Non-bendable, rigid assembly |
| Standard Lead Length | 300 mm | 300 mm | 300 mm | 300 mm | 350 mm |
| Lead Wire | PTFE; optional SS braided | PTFE; optional SS braided | PTFE; optional SS braided | PTFE; optional SS braided | PTFE; SS braided by default |
| Max. Actual Working Temperature | 520°C | 520°C | 500°C | 500°C | 420–500°C depending on version |
| Max. Actual Watt Density | 7 W/cm² | 8 W/cm² | 9 W/cm² | 7.5 W/cm² | 10–12 W/cm² |
| Thermocouple | K-type / J-type optional | K-type / J-type optional | K-type / J-type optional | K-type / J-type optional | K-type / J-type optional |
| Customization | Yes | Yes | Yes | Yes | Yes: ID, OD, length, power |
| Main Application | Large hot runner nozzles, manifold sleeves | Medium hot runner nozzles, continuous-run molds | 3C and medical precision molds, narrow gaps | Micro hot runner, electronics and medical molds | Optical and high-precision medical mass production |
How to Choose the Right Coil Heater
The most suitable configuration depends on the available installation space, required contact area, bending requirements, watt density, operating temperature and production conditions.
- Round: Suitable when flexibility and easy installation around larger hot runner nozzles are important.
- Square: Suitable when a larger contact surface and higher watt density are required for continuous production.
- Flat / Rectangular: Suitable for narrow installation spaces where greater contact area and efficient heat transfer are required.
- Micro Mini: Designed for compact hot runner nozzles, miniature molds and applications with very limited installation space.
- Pressed-in Brass: Suitable when rigid installation, close contact, repeatable heat transfer and production consistency are required.
Explore the Five Coil Heater Series
Each configuration is designed for a different combination of installation space, heating performance and production requirements. Visit the individual product pages for detailed specifications, available sizes and customization options.
- Round Coil Heater – flexible round-profile heating for larger hot runner nozzles and manifold applications.
- Square Coil Heater – larger contact area and higher watt density for continuous-run injection molding.
- Flat / Rectangular Coil Heater – compact flat-profile design for narrow gaps and precision molds.
- Micro Mini Coil Heater – miniature heating for compact hot runner and precision applications.
- Pressed-in Brass Coil Heater – rigid close-contact heating for precision and mass-production molds.
Custom Coil Heater Solutions
All five configurations can be customized according to the heating and installation requirements. Depending on the design, customization can include inner diameter, outer diameter, cross-section, heating length, wattage, voltage, lead length, lead direction and thermocouple configuration.
For applications with strict temperature requirements, the allowable watt density and working temperature should be selected according to the heated component, installation condition and heat dissipation environment.
Coil Heater Applications
- Hot runner injection molding systems
- Plastic injection molding nozzles
- Precision optical lens molds
- Medical plastic component molds
- 3C electronics injection molds
- Packaging machinery
- High-cycle injection molding equipment
- Precision heating assemblies
Request a Coil Heater Quote
Need help selecting the right configuration? Send us your heater cross-section, inner diameter, heating length, voltage, wattage and quantity. If you have a drawing or sample, we can also supply a custom heating assembly according to your requirements.
Email: Amy-Easewise@tzheater.com
WhatsApp: +86 188 8318 8154
Hanna – Sales
Email: Hanna-Easewise@tzheater.com
WhatsApp: +86 173 5163 6811
Custom coil heater configurations are available for hot runner and precision injection molding applications.