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Title: Butler Technologies Unveils Next Gen Flexible Heaters for EV and Medical Applications

West Wayne, Pennsylvania, United States, 1st Aug 2025 - Flexible heaters are thin, bendable heating elements made by printing conductive and resistive inks onto plastic films. Unlike bulky wire-based heaters, these printed heaters are typically only 0.05–0.76 mm thick and can conform to complex shapes. For example, Butler Technologies (BTI) notes their printed heaters have a “thin, flexible, and sometimes stretchable” form factor that can even flex with the human body. These heaters are already used in apparel, aerospace, automotive, and medical devices, and demand is rising rapidly, especially as electric vehicles (EVs) and advanced medical technologies require compact, efficient heating solutions.Overview of Flexible HeatersFlexible printed heaters are essentially heating films. Conductive busbars and resistive ink patterns are screen-printed onto a polymer substrate (such as polyester, polyimide/Kapton, or thermoplastic polyurethane. When voltage is applied, these printed traces generate heat via Joule heating. By choosing inks and patterns precisely, engineers can tailor the heater’s performance. The result is an ultra-thin, bendable film heater that can be laminated onto fabrics, plastic panels, or even embedded within devices. Because they are so thin and flexible, these heaters can go in places traditional heaters can’t – for example, inside wearable garments or molded into car parts.Flexible heaters come in two main styles: fixed-resistance heaters (with a nearly constant resistance) and PTC (positive-temperature-coefficient) heaters. PTC heaters use carbon-based inks that automatically limit their temperature – as the heater warms up, its resistance rises, preventing overheating. Butler Technologies and others offer both types: fixed-resistance p...

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