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Customer Support

Custom Thermal Systems & Components

Hi-Watt sources thermal system components for industrial clients around the United States. Although we carry stock items, including sensors and some heaters, available for same-day shipping, over 40% of our business involves designing custom thermal system solutions. We’re not just a supplier. Our in-house team can upgrade and modify existing controls and heaters or build new thermal system components that match your exact requirements.

How Our Process Works

1. Consultation

Contact a Hi-Watt representative at (855) 467-5628, and let us know your current process heating challenges and application requirements. We offer same-day support.

2. Building & Testing

Our team sources the relevant parts for your new thermal system component, whether that’s a heater, controller, or complete system, and starts the custom build. The timeline varies based on project complexity and part availability; our representatives will provide a more accurate turnaround time for your specific application. All systems and system components are thoroughly tested in-house in our Michigan-based facility to ensure they meet your specifications.

3. Shipment

We’ll ship your components and/or system to you with installation instructions and maintenance recommendations. Controllers and process heaters are designed for out-of-the-box operation. After you implement our custom solution, our support doesn’t end there. Our team is always available for remote troubleshooting, calibration services, and field repairs.

Our Capabilities

Hi-Watt supports clients in industries ranging from biopharma and chemical processing to military/defense and aerospace. We can build thermal systems and related components to meet industry compliance requirements, withstand specific environmental challenges, whether chemical exposure or extreme vibration, and sized properly for your application.

Control Panels

Control Panels

Hi-Watt supports legacy retrofits and upgrades and can build customer electric control panels, power distribution panels, HMI operator consoles, single- and multi-hole pushbutton stations, remote I/O enclosures, junction boxes, and more.

Custom Heaters

Process Heaters

We can build process heaters with multi-zone heating and independent zone control, integrated thermocouples for better accuracy, and to withstand environmental challenges like high temperatures, high pressure, water exposure, and chemical exposure. We can meet UL, CSA, ATEX, and IECEx requirements.

Portable Temperature Control Consoles

Temperature Control Consoles

Get custom single-zone, dual-zone, or quad-zone temperature control consoles made from carbon, stainless steel, or aluminum. All components are replaceable and designed for your environment. All inputs are pre-wired to improve installation ease, and we can design UL-compliant consoles, depending on application requirements.

Heated Platens

Heated Platens

If you’re in the thermoforming or compression molding industries, we can help you improve surface contact and heating uniformity by designing a custom heated platen system. Our custom solutions include CAD platen design, wattage calculations, sensor selection, and a zone control strategy.

Brand Partners

Our Work

See Our Impact

Hi-Watt takes pride in helping our customers solve process heating challenges. We’ve developed custom thermal system solutions for countless clients across chemical processing, plastics processing, biopharma, military, and food and beverage industries. See some of our past projects.

A person is spraying a coating on metal

Hi-Watt Helps Plating Factory Extend Heater Life

A plating factory was spending thousands of dollars on heater replacements each quarter. After performing a Thermal System Assessment, Hi-Watt helped our customer redesign their process heater, significantly extending heater life and reducing unplanned downtime.

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A heated platen system

Hi-Watt Designs a Multi-Zone Heated Platen System

A customer needed a turnkey heated platen system (with a controls package) in 7 weeks, a project that typically takes months to achieve. Instead of delivering separate components, our team successfully designed the thermal system within the requested timeline.

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A test chamber

Hi-Watt Designs Environmental Chamber Controls

A biopharma OEM needed a single control solution that could regulate humidity, temperature, airflow, and motion across multiple environmental chambers. Hi-Watt successfully designed and delivered a complete controls package and provided on-site support throughout every phase of the project.

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A window overlooking two scientists in a lithium ion battery research lab

Hi-Watt Delivers Cartridge-Style Heaters to Defense Testing Facility

A government testing facility had unsuccessfully tried different heating solutions. After contacting HI-Watt, our engineering team met with the client on-site several times to review application requirements and design iterations. Once a design was approved, Hi-Watt produced rapid prototypes for qualification testing, which passed with no issues. After approval, we were able to produce and manage monthly shipments of 50 heaters.

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Value-Added Services

Hi-Watt is a customer-first supplier. If you experience any issues or challenges after you’ve implemented your new process heater, controls package, or thermal system, we can provide:


On-Site Support


Remote Troubleshooting


Sensor Installation Guidance


Calibration Services


Field Repairs


Inventory Management Assistance


Replacement Components

Talk to the experts!

Have questions? Our dedicated sales team is here to help! With a track record of addressing 95% of inside sales quoting requests within 3 hours, trust our experts to provide timely and comprehensive assistance.

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