Case Study #075: How to Improve the Life of a Mica Band Heater A customer phoned our engineering department here at Thermal Corporation complaining that he was experiencing very poor life with a mica band heater — a life of only one week! He explained that the application was to heat a flange that was attached to a gate at the end of an extruder. The extruder was adding a layer of nylon to wire-in cross-head die. The flange sat between the gate and the cross-head die. (The cross-head die had its own separate heater). The flange also had a thermocouple, extending radially, out of it. The application looked something like the image you see below. The flange had a width of 1” or so and a diameter of 5”. The mica band heater was our configuration 514 with a hose at 90° from the gap

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