The final inspection was carried out by our in-house quality team along with a third-party inspector from TÜV Rheinland, who verified that all units meet the strict requirements of the German automotive industry. Each heater in this batch is 400V, 1000W, 16mm diameter by 400mm long, made from Incoloy 800 alloy to withstand the high temperatures and corrosive environment of the mold heating process. The high-density design delivers 15W/cm² of watt density, which allows for rapid heat-up times-critical for the client's just-in-time production schedule.
The client is expanding their EV battery housing production line at their Stuttgart facility, and needed heaters that could maintain precise temperature control within ±1°C to ensure consistent quality of the molded parts. Our engineering team worked closely with the client's mold designers to customize the heater layout, including the placement of thermocouple holes and the length of the cold zones, to fit perfectly into the existing mold configuration.
During the inspection, we tested 100% of the units for power tolerance (±5%), insulation resistance (≥500MΩ at 500V DC), and high-pot strength (1500V for 1 minute without breakdown). We also conducted a 72-hour continuous burn-in test on a random sample of 50 units to verify long-term stability, and all samples performed within the specified parameters. The client's quality manager was particularly impressed with the consistency of the heater dimensions, which were all within ±0.05mm of the specified tolerances-tighter than the industry standard of ±0.1mm.
