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Kapton flexible heaters (or PI film heaters) are made with a thin metal foil (.001''-.002''), usually a nickel base alloy (Ni+Cr), as the resistance foil. The resistance pattern to be etched is designed in CAD and transferred to the foil, which is laminated to the insulating substrate, polyimide film. The top layer is then added and laminated for Kapton heaters. At final, lead wires are attached to the heater and insulated with epoxy cement to complete the heater. The PI film heater has exceptional heat transfer compared to wire wound heater, due to its large flat surface area. It can deliver more uniform heat profiles with higher power density, providing longer operating life. It can also be zoned with distributed wattage or separate heating circuits to compensate for load variations.