In a design for a heated block I am working on I only have the space for a 6mm X 10mm hole for my heating element to be inserted into.

Originally I had planned to use a 40W heater cartridge but the smallest I can find is 6mm x 20mm and the extra 10mm that would stick out the block would be inconvenient as I want to insulate the area around this from the heat.

Is there a good alternative to a heater cartridge that would fit my specs?

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    $\begingroup$ Back in the day people used large resistors for heating elements...but i assume you only have a hole on one side...the heater carts are nice things..but i couldn’t find one only 10mm long either...can you change your block size? $\endgroup$ – morbo Feb 5 at 17:13
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    $\begingroup$ I would be concerned about burning up a resistor that small in an enclosed space. Resistor ratings typically assume air heat dissipation at normal ambient temp. 40W is a lot. $\endgroup$ – Tiger Guy Feb 5 at 20:16
  • $\begingroup$ That's interesting, I hadn't thought of that. I could make it a through hole without much issue, I can't make the block much bigger due to access restrictions. Do you think a resistor would be suitable for temperatures around 200°C? @morbo $\endgroup$ – FEA42 Feb 5 at 20:33
  • $\begingroup$ In this situation it would be enclosed by aluminium alloy 1xxx and operate at temperatures around 200°C, do you think these conditions could potentially lead to the resistor burning up? @ScottDunnington $\endgroup$ – FEA42 Feb 5 at 20:35
  • $\begingroup$ I think it's a specialty application. I wouldn't count on a regular ceramic resistor holding up. This question might go better on the Electrical Engineering SE. $\endgroup$ – Tiger Guy Feb 5 at 20:37

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