In technical applications such as wind tunnel models, reliable and uniform heating is essential. This becomes especially challenging when the internal shape of a model is not flat or straight, but instead conical, slightly curved, or otherwise complex. In these situations, standard heating solutions quickly reach their limits. This is clearly illustrated in the customer case where flexible film heaters are used in square patches. While they perform well, the geometry of the model leads to uneven heat distribution. We provide a high-quality custom solution specifically designed to overcome these challenges.
The challenge of uniform heat distribution in a conical shape
Most standard film heaters are designed in simple shapes such as rectangles or squares. These work well on flat surfaces, but as soon as the surface has a complex geometry such as a conical frustum with a slight curvature, problems arise. The heater cannot make proper contact everywhere, resulting in inconsistent heat transfer.
In practice, this means some areas of the model become too hot, while others remain cooler. In applications like wind tunnel testing, where precision is critical, these temperature deviations can negatively impact measurement accuracy. This creates the need for a heating solution that precisely follows the shape of the model and ensures consistent thermal performance across the entire surface.
Specialist in custom heating solutions
We are globally recognized as a specialist in the design and production of custom electric heating elements. Where standard products fall short, Backer‑Wilson excels. With extensive engineering expertise, they can develop heaters tailored entirely to the specific requirements of the application.
In cases like this, the heater no longer needs to conform to a standard shape. Instead, it is designed to match the exact geometry of the model. Every aspect is taken into account, including surface area, curvature, mounting position, and desired temperature distribution.
Custom polyimide film heaters
One of the most suitable solutions for this type of application is a flexible polyimide film heater. These heaters are thin, lightweight, and highly flexible, making them ideal for installation on complex surfaces. Our key strength lies in producing these heaters fully customized.
This means the heater can be designed to match the conical shape of the wind tunnel model. Instead of multiple square patches, a single continuous heating element can be manufactured to follow the exact contours. This greatly improves surface contact and minimizes heat loss.
Additionally, these heaters can be engineered with strategically designed heating circuits. This allows heat output to be distributed precisely, ensuring an even temperature across the entire model. This level of control is essential for applications where accuracy and repeatability are critical.
Integration of multiple heating zones
For complex geometries, a single uniform heating circuit is often not sufficient. We offer the possibility to integrate multiple heating zones within one element. This means different sections of the heater can be controlled independently.
In a conical application, for example, the wider and narrower sections of the model may require different heat outputs. By dividing the heater into zones, the temperature can be fine-tuned based on geometry and local heat loss. This results in a significantly more precise temperature profile compared to standard solutions.
This multi-zone approach enables highly controlled and uniform thermal conditions, even in challenging environments.
Alternative to rigid heat strips
Flexible custom heaters are a good alternative to rigid heat strips. They combine precise shaping, easy installation, and optimal heat transfer. By designing the heater to perfectly fit the model, the need for a rigid solution is eliminated while achieving better overall performance.
If additional structural support is required, we can also develop hybrid solutions that combine flexibility with mechanical stability.
Engineering and collaborative design process
What truly sets us apart is their collaborative engineering approach. Working closely with the customer, they develop a solution based on technical drawings and detailed specifications.
The design process considers not only the physical shape of the heater but also key performance factors such as electrical connections, power density, heat-up time, and operating conditions. This comprehensive approach ensures that the final product is not only a perfect fit mechanically, but also optimized for performance.
For engineers and designers, this means there is no need to compromise. Instead, they receive a heating solution specifically engineered to meet their exact technical requirements.
Applications in wind tunnel and test environments
In wind tunnel models and other testing environments, temperature control is often a critical parameter. Even small variations can affect measurement results and compromise data accuracy. By using custom heaters from Backer‑Wilson, these risks can be significantly reduced.
The ability to tailor the heater to the exact shape of the model, combined with precise control over heat distribution, makes this solution particularly suitable for such demanding applications. It enables a stable and controlled thermal environment, even within complex geometries.
By choosing a custom solution from Backer‑Wilson, the immediate heating challenge is addressed while also creating a robust foundation for future optimization and high-performance testing scenarios. Contact us, and heat your application the Backer way!
