There is not one set approach to manufacturing skis or snowboards in the United States. Like many art forms, there are different ways to make the equipment used in the billion-dollar snow sports market.

These include varied processes, materials, and tools. Each company uses its own methods. A custom ski manufacturer faced a problem with silicone rubber heaters. This issue arose during their curing and vinyl transfer process.

Even though these heaters were made to the customer's exact needs, they were burning out too soon. This caused delays in production and inefficiencies.

Thermal Devices, was called in to investigate. After reviewing the system, they found several factors causing the issue. They also asked Tempco for help. The solution involved a combination of engineering adjustments that not only fixed the immediate problems but also improved the overall reliability and lifespan of the heaters.

The Problem: Heater Failures and Overheating

The custom ski manufacturer faced ongoing problems with silicone rubber heaters. The manufacturer made these heaters to the exact size and electrical needs specified by the customer. Despite these specifications, the heaters weren’t performing as expected. The main issues identified were:

1. Excessive Heat and Pressure at the Lead Wire End: The mold used in the production process was irregularly shaped, creating uneven pressure on the heaters. This resulted in heat being concentrated at the lead wire end, causing overheating and premature failure of the heaters.
2. Gaps Between the Heater and the Product: Due to the irregular shape of the mold, there were small gaps between the heater and the product. This created areas where heat was not being applied evenly, adding stress to the heater and further contributing to its failure.
3. Control System Issues: The original control panel used an ON/OFF control with a 20-second time base, cycling the heaters on and off using solid-state relays. This setup led to rapid temperature fluctuations, overshoot, and inefficiencies, which ultimately affected the lifespan of the heaters.

The Solution: Heater Design Improvements

Tempco and Thermal Devices worked together to address these issues. After evaluating the design and testing the heaters, they implemented a series of changes to improve both performance and durability.

1. Added reinforcement to the heater to reduce the risk of overheating and extend its lifespan.
2. Repositioned the lead wire to alleviate stress on both the wire and the heater.
3. Lowered the watt density of the heaters to enhance their life expectancy.
4. Implemented PID (Proportional-Integral-Derivative) control and reprogrammed the control panel to improve efficiency and performance.

The Result: Improved Heater Reliability

Once the design changes were implemented, the manufacturer saw immediate improvements. The heaters began to operate more reliably, with significantly fewer failures. The temperature control improved, and the heaters could reach the desired settings without overheating or failing. The manufacturer also noticed improved overall efficiency in their production process.

Lessons Learned: Key Takeaways for Manufacturers

For manufacturers facing similar issues with heater performance, there are several key takeaways from this case:

1. Consider the Entire System: Heater problems are often linked to more than just the heating element itself. Issues like mold shape, surface contact, and control settings can all contribute to premature failure. It’s important to look at the system as a whole when troubleshooting.
2. Work with Experienced Partners: The combined expertise of Tempco and Thermal Devices was critical in solving the issue. Their years of experience in heater design and troubleshooting allowed them to quickly identify the root causes and propose effective solutions. Manufacturers should seek out partners with specialized knowledge to help diagnose and resolve complex heating problems.
3. Optimize Heating Parameters: Small adjustments to watt density and control settings can have a big impact on heater life. Manufacturers should regularly review their heating systems to ensure they are running efficiently and not overloading the equipment.
4. Ensure Proper Control System Settings: The control system plays a crucial role in regulating temperature and preventing overheating. Adjusting the control system to use more precise methods, like PID control, can significantly improve heater performance and extend its life.
5. Regular Maintenance and Monitoring: Heater systems should be regularly checked and maintained. Even small issues like uneven surface contact or incorrect control settings can lead to bigger problems down the line. Periodic reviews can help ensure that heaters continue to perform at their best.

Final Thoughts: Improving Heater Reliability for Long-Term Success

The collaboration between Tempco and Thermal Devices demonstrates how a systematic, well-engineered approach can solve complex heating problems. Tempco and Thermal Devices carefully looked at the problem and made key changes. This helped fix the heater failures and improve the custom ski manufacturer’s production process.

This case shows how important it is to check the whole heating system when solving issues. Making sure everything—from the settings and control system to how parts are placed—is set up right can improve both performance and reliability. If you're facing similar problems, working with experts can help you find lasting solutions and avoid expensive downtime.

Tempco and Thermal Devices have a combined 75+ in business and that heater knowledge can transfer to troubleshooting applications. The end customer has experienced trouble-free performance from their heaters since the team made the design changes. Tempco wants to thank Thermal Devices in Maryland for their support over the years.