The Challenge: Extreme Heat with Precision Control

Superplastic thermoforming is a precision process used in high-performance aerospace manufacturing. To mold components like titanium aircraft parts, manufacturers must reach extreme temperatures—around 1700°F—to make the metal malleable, like Silly Putty.

Traditionally, these processes have relied on gas-fired heat systems which introduce challenges around environmental compliance, system footprint, and energy efficiency. But for one Ramco customer in the aerospace sector, moving to electric heat wasn’t just a sustainability goal—it was a technical necessity.

The problem? Standard electric heaters can’t withstand those temperatures for long.

Doug Lybarger, an Applications Engineer at Ramco, explains:

“When you're running above 1500°F, conventional heaters eventually fail. Nickel migrates through ceramic insulation on a molecular level, and over time, you get a short. When that happens, the heater doesn't just fail—it can weld itself to the surrounding die. It’s catastrophic.”

The customer needed an electric heater that could match the thermal demands of titanium forming—without the constant risk of failure or downtime.

The Solution: Watlow’s MULTICELL™ Cartridge Heater

Enter the Watlow MULTICELL™ insertion cartridge heater, a rugged, high-performance heater engineered for extreme heat environments.

This innovative solution provides:

  • Temperature uniformity across multiple independent heating zones
  • Reduced risk of failure from nickel migration
  • A robust ceramic structure that maintains integrity even when internal elements approach molten conditions
  • Ease of installation and removal thanks to a loose-fit cartridge design
Unlike traditional cartridge heaters that degrade at high temps, the MULTICELL’s unique internal architecture withstands the heat—even when the internal steel resistance elements go molten. The ceramic insulator holds the structure together, preventing meltdown and allowing extended service life.

“It’s kind of mind-blowing,” says Doug. “Inside, you have steel elements that technically go molten, but everything holds because of the ceramic. That’s how it avoids shorting out and becoming a maintenance nightmare.”

The Application: Superplastic Thermoforming in Aerospace

The MULTICELL heater was selected for use in a superplastic titanium forming press at an aerospace facility. In this application, the heater:

  • Provides tight temperature control and uniformity
  • Replaces gas-fired systems, eliminating emissions at the plant level
  • Supports the customer’s move toward green initiatives without sacrificing performance
  • Reduces downtime by avoiding catastrophic heater blowouts
Doug explains the added sustainability benefit:

“Even though electricity has to come from somewhere, removing gas from the plant floor simplifies compliance and safety. This is a step toward cleaner heat—and a smarter process overall.”

The Heater Configuration: Custom Fit for a Demanding Process

Because superplastic titanium forming requires precise control across varying part geometries, the heater specifications were customized for each press. Heater length and wattage were selected based on press tonnage, die size, and part dimensions—ensuring optimal thermal coverage and uniformity.

While every MULTICELL heater is made to order, the core design remains consistent across applications. Ramco worked closely with the manufacturer to align the custom build with process needs, making sure each unit delivered maximum durability and performance in high-cycling, high-heat conditions.

“These presses see repeated heating and cooling,” Doug notes. “The MULTICELL is built to handle that kind of expansion and contraction without failure—so uptime stays high and maintenance headaches stay low.”

The Result: Clean Heat, Lower Risk, Longer Life

The customer now has a clean, durable, and precise solution for titanium forming—one that outperforms traditional heaters and helps future-proof their operation against rising energy and environmental demands.

Ramco’s team played a pivotal role by identifying the right product, explaining its performance advantages, and ensuring proper application fit.

“This is where the AE team shines,” says Doug. “It’s not just about quoting a part number. It’s about knowing when a customer’s process demands something different—and finding the right solution before things go wrong.”


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