Rapid Fabrication Program

Delivering High Quality Thermal Components on Compressed Timeframes

The Rapid Fab program from CAS features high quality manufacturing of industrial heaters.

Cast Aluminum Solutions is respected supplier of precision engineered thermal components to the semiconductor, medical device, commercial foodservice, and aerospace markets.

Our Rapid Fab Program applies this design and manufacturing expertise toward the production of high-quality industrial products, using standardized components, delivered on abbreviated timeframes.

  • What You Need: Perfect for replacement parts, prototypes, proof-of-concepts, and low-volume runs
  • When You Need It: As short as 2-3 weeks on non-heated parts, 3-4 weeks on heated components
  • Components are In-Stock: The program is based on the use of standardized, in-stock or readily-available substrate materials, heaters, temperature sensors, and component fittings.
  • Many Options: Stainless steel and aluminum substrate options. Heater choices include tubular, cable, and cartridge heaters, with several options for temperature sensors, lead wires and power connectors.
  • Fabricated for Performance: CAS employs distinct fabrication techniques, matched to your substrate & heater pairing, ensuring each design configuration performs at a high level over a long lifecycle.
  • Its Your Design: Rapid Fab projects are custom-machined to meet each customer's unique form, fit, and function specifications..

Let's Get Started on Your Project

The below will walk you through the details of our Rapid Fabrication Program, and allow you to Request a Quote.

Click Picture for Rapid Fab Examples
  • The Rapid Fab Program utilizes a menu-driven process to select substrate materials, heaters, temperature sensors, leadwires, and power connectors. See the tables below for the full list of options, or click the "Quote Request Tool" to get started.
  • Dimensions and surface finishes are determined by the customer. The Quote Request Tool will allow you to upload PDF docs for your project's Schematics or Dimensional Drawings.
  • Rapid Fab quotes are generally completed and sent to customers via email within 24 hours.
  • Parts are not required to have a heating or cooling function.
  • Projects utilizing tubular heating elements will be constructed using our proprietary Interference Fit Construction. This proprietary technique optimizes thermal transfer and ensures long heater life.
  • Projects utilizing cable heaters will use a milled groove construction, and require a backing plate.

Substrate Options

  • Aluminum and Stainless Steel substrate materials are offered
  • The size limitations noted here denote max dimensions for Rapid Fabrication program parts
  • Parts with larger substrate dimensions may still be manufactured, although not part of the Rapid Fab program
SUBSTRATE MATERIAL CHOICES 
TYPE OF METAL SQUARE CUT MAX SIZES CIRCLE CUT MAX SIZES 
Aluminum (6061-T6 Grade) 30” x 30” max. (76 cm) 20” Max. Diameter (50 cm) 
Stainless Steel (316 / 316L Grade) 30” x 30” max. (76 cm) 20” Max. Diameter 

Heater Options: Tubular Heaters

Tubular Heaters are integrated via CAS's Interference Fit Construction (IFC), delivering superior heat transfer due to the heater’s intimate contact with the substrate.

Tubular Heaters for Aluminum 
Uses IFC (Interference Fit Construction) 
Maximum Recommended Operating Temperature for Tubular Heater in Aluminum: 800°F (426°C) 
Heater Code  Sheath Diam. Inch (cm)  Heated Length Inches (cm)  Volts  Watts 
101  0.260 (.66)  30.0 (76.2)  208  1200 
102  114.6 (291.0)  1500 
103  47.1 (119.6)  2000 
104  66.0 (167.6)  2250 
105  90.0 (228.6)  2700 
106  110.0 (279.4) 
107  50.5 (128.2)  2800 
108  55.1 (139.9)  2800 
109  0.315 (.80)  70.0 (177.8)  4200 
110  100.0 (254.0)  5400 
111  120.0 (304.8) 
112  115.1 (292.3)  6200 
113  0.260 (.66)  30.0 (76.2)  240  1600 
114  66.0 (167.6)  3000 
115  90.0 (228.6)  3600 
116  110.0 (279.4) 
117  0.315 (.80)  70.0 (177.8)  5600 
118  100.0 (254.0)  7200 
119 120.0 (304.8) 

Tubular Heaters for Stainless Steel 
Uses IFC (Interference Fit Construction) 
Maximum Recommended Operating Temperature for Tubular Heater in SS: 1202°F (650°C) 
Heater Code  Sheath Diam. Inch (cm)  Heated Length Inches (cm)  Volts  Watts 
201  0.260 (.66)  114.6 (291.0)  208  1500 
202  66.0 (167.6)  2250 
203  90.0 (228.6)  2700 
204  110.0 (279.4) 
205  0.315 (.80)  120.0 (304.8)  5400 
206  0.260 (.66)  110.0 (279.4)  240  3600 

This tubular heater fits a milled groove industrial heater, improved by the IFC process from CAS in Batavia.
  • Cold Ends: 2 - 6 inches
  • Tubular heaters can be operated at below the stated voltages, resulting in reduced (derated) wattage output.

Heater Options: Cable Heaters

Cable Heaters require a backing plate, and will utilize a standard Milled Groove process to integrate the heater with the substrate.

Cable Heaters for Aluminum 
Uses Milled Groove Construction 
Maximum Recommended Operating Temperatures for Cable Heater in Aluminum: 800°F (426°C) 
Heater Code  Sheath Diam. 
Inch (mm) 
Sheath Length
Inches (cm) 
Adapter 
Diameter 
Inch (mm) 
Adapter 
Length 
Inch (mm) 
Volts  Watts 
301  0.125 (3.17)  26.3 (66)  0.38 (9.65)  2.00 (50.8)  120  270 
302  0.125 (3.17)  138.1 (350)  0.38 (9.65)  1.26 (32.0)  194  3350 
303  0.188 (4.77)  82.0 (208)  0.38 (9.65)  1.13 (28.7)  208  726 
304  0.125 (3.17)  108.5 (275)  0.38 (9.65)  2.50 (63.5)  1033 
305  0.188 (4.77)  123.3 (313)  0.38 (9.65)  1.13 (28.7)  1309 
306  0.125 (3.17)  214.8 (545)  0.38 (9.65)  1.50 (38.1)  1464 
307  0.125 (3.17)  157.6 (400)  0.38 (9.65)  2.00 (50.8)  2000 
308  0.094 (2.38)  136.5 (346)  0.25 (6.35)  1.13 (28.7)  945 

Cable Heaters for Stainless Steel 
Uses Milled Groove Construction 
Maximum Recommended Operating Temperature for Cable Heater in SS: 842°F (450°C) 
Heater Code  Sheath Diam. 
Inch (mm) 
Sheath Length 
Inches (cm) 
Adapter 
Diameter 
Inch (mm) 
Adapter 
Length 
Inch (mm) 
Volts  Watts 
401  0.125 (3.17)  26.3 (66)  0.38 (9.65)  2.00 (50.8)  120  270 
402  0.125 (3.17)  138.1 (350)  0.38 (9.65)  1.26 (32.0)  194  3350 
403  0.188 (4.77)  82.0 (208)  0.38 (9.65)  1.13 (28.7)  208  726 
404  0.125 (3.17)  108.5 (275)  0.38 (9.65)  2.50 (63.5)  1033 
405  0.188 (4.77)  123.3 (313)  0.38 (9.65)  1.13 (28.7)  1309 
406  0.125 (3.17)  214.8 (545)  0.38 (9.65)  1.50 (38.1)  1464 
407  0.094 (2.38)  136.5 (346)  0.25 (6.35)  1.13 (28.7)  945 

  • Cable heaters can be operated at below the stated voltages, resulting in reduced (derated) wattage output.

Tubular or Cable Heater? Consider These Factors

The choice of Tubular vs. Cable Heater affects the construction format of your part. Tubular Heaters are integrated using our proprietary Interference Fit Construction (IFC), causing the heater to have intimate contact with the substrate. Cable Heaters are integrated using a standard Milled Groove process, which requires the integration of backing plates.

Industrial heater manufacturing optimized with IFC milled groove process, perfected by CAS in the Rapid Fabrication program.

Tubular Heaters are integrated to substrates using our IFC technique, which results in optimal heat transfer and longer heater life.

IFC vs. MILLED GROOVE - WHAT’S THE DIFFERENCE ? 
Interference Fit Construction Milled Groove 
  • Used on tubular heaters
  • No backing plate required
  • Tubular heaters are thicker, with a wider bend radius
  • Heater is pressed in using a proprietary CNC process
  • Because the heater has intimate contact with the substrate material, thermal transfer is optimized, efficiency is increased, and lifespan is often increased
  • Used on cable heaters
  • Requires backing plate
  • Cable heaters are thinner, with a tight bend radius
  • Heater is manually fit into the subassembly
  • The tighter bend radius can lead to better thermal uniformity, but efficiencies are lower and heater lifespan can be shorter
Cast Aluminum Solutions is a manufacturer of milled groove industrial heaters like this, with options for SST or Aluminum.

Cable Heaters are integrated via a traditional Milled Groove process, requiring the integration of a backing plate or similar mechanism.

Heater Options: Cartridge Heaters

Substrates can be machined to accommodate single heaters or multiple Cartridge Heaters.

Cartridge Heaters - Appropriate for Aluminum or Stainless Steel
All are 5/8" (15.8 mm) Diameter
Maximum Recommended Operating Temperature for Cartridge Heater in Aluminum: 800°F (426°C)
Maximum Recommended Operating Temperature for Cartridge Heater in SS: 842°F (450°C)
Heater Code  Length Inches (cm)  Watts At 240 Volt  Watts At 208 Volt 
501  3.0 (7.62)  750  560 
502  4.0 (10.16)  750  560 
503  4.0 (10.16)  1000  750 
504  5.0 (12.7)  750  560 
505  5.0 (12.7)  1000  750 
506  5.4 (13.7)  800  600 
507  6.0 (15.24)  750  560 
508  6.0 (15.24)  1000  750 
509  6.0 (15.24)  1500  1125 
510  7.0 (17.78)  1000  750 
511  7.0 (17.78)  1500  1125 
512  8.0 (20.32)  850  630 
513  8.0 (20.32)  1000  750 
514  8.0 (20.32)  1500  1125 
515  8.0 (20.32)  2000  1500 
516  10.0 (25.4)  750  560 
517  10.0 (25.4)  1000  750 
518  10.0 (25.4)  1500  1125 
519  10.0 (25.4)  2000  1500 
520  12.0 (30.48)  900  675 
521  12.0 (30.48)  1000  750 
522  12.0 (30.48)  1500  1125 
523  12.0 (30.48)  2000  1500 
524  14.0 (35.56)  3700  2775 

Industrial heaters manufactured by CAS use these cartridge heater types in SST plates and rings.
  • Cartridge Heaters can be operated at below the stated voltages, resulting in reduced (derated) wattage output.
  • Power leads are 24" (60 cm) Teflon or MGT

Temperature Sensors

We offer popular TC and RTD Temperature Sensors, which can be integrated into heated parts to control operating temps and protect against overheating.

Temperature Sensors 
All Thread into a 1/16" NPT Mounting Hole 
Sensor Code  Sheath Diam. Inch (mm)  Omega Mini Male Connector  Connector Quantity  Sensor Description 
0.063 (1.60)  HMPW-J-M  J-Type Thermocouple, Single Junction 
0.063 (1.60)  HMPW-K-M  K-Type Thermocouple, Single Junction 
0.125 (3.17)  HMPW-J-M  J-Type Thermocouple, Dual Junction 
0.063 (1.60)  HMPW-K-M  K-Type Thermocouple, Dual Junction 
0.125 (3.17)  MTP-U-M  RTD, 3 Wire, 100Ω, Single Junction 

Industrial heaters manufactured by CAS feature temperature sensors such as RTDs or TCs in K-Type or J-Type.

Power Connectors

These industry-standard Power Connector options allow customers to easily integrate Rapid Fab parts into their existing process machine.

Power Connector Menu 
Lead Wires: 18 AWG Gauge, 24" (61 cm) Long 
CAS Supplied Connection (TE #)  Customer Supplied Connection 
Power 
Option 
Connector 
Body 
Connector 
Pin
Cable 
Clamp 
Mating 
Body 
Mating 
Socket 
Mating 
Clamp 
Power Connector 
Description 
N/A  Bare Lead Wires, Teflon 
N/A  Bare Lead Wires, MGT 
1-480700-0  350218-7  1-640720-0  1-480701-0  350550-7  1-640720-0  3 Pin Mate-N-Lok, Teflon 
3 Pin Mate-N-Lok, MGT 
206429-1  1-66099-5  1-206062-4  206060-1  1-66101-9  1-206062-4  4 Pin CPC, Teflon 
4 Pin CPC, MGT 

These power connectors are used on industrial heaters manufactured by CAS in the Rapid Fabrication program.

Rapid Fabrication Quote Request Tool

Please click through the below interface, selecting the options required to build your Rapid Fab part. At the end, you’ll be allowed to upload a schematic or print of your design. A CAS Technician will then contact you to follow-up and quote the project. If certain aspects of your project are not addressed in the Quote Request Tool, that’s okay, as those issues can be discuss with your CAS Technician.


AluminumStainless Steel


InchesCentimeters

Length

Width

Height

  • Rapid Fab projects assume the use of relatively standard tooling (custom tooling may add to leadtimes).
  • CAS reserves the right to add fixture holes, as needed.
  • Customer drawings are not required: in such cases, project will assume “standard CAS tolerances” on ma-chined features.
  • Outside services or 'off menu' components may add to leadtimes.
  • To qualify for the Rapid Fab Program, parts must be no larger than listed below:
  • Max Length: 30" (73 cm), Max Width: 30" (73 cm), Max Height/Thickness: 3" (7.6 cm).
  • Parts larger than this are still manufacturable, but may go through a different program.

- Select Heater -

- Select Temperature Sensor -

- Select Power Connector -


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