Hello All, Greetings. I am new to this forum. I am working for a heater project, in which we use plastic (PA66) over molded on aluminum (6061-T6) body for melting corrosive liquids (similar to sea water). The Aluminum body is heated by means of Positive temperature coefficient material (PTC) from a 12V battery. The problem we face is, the quantity of heat is not sufficient to melt the stated quantity of liquid in a specified time. We have constrains like not to change the size of the outer surface of heater and supplied voltage. But room to play inside the heater. Hence i am looking to use copper strip placed inside slots provided in Aluminum body or to wind copper wire wound around Aluminum body and then over molding by plastic. In these solutions, i have bottle neck like whether these copper strip will really contribute for extra heating of Aluminum body for the given voltage ? The copper material having thermal conductivity (400 W/m-K) will contribute for effective heat transfer but the resistivity is less (1.72e-8 Ohm-m). Will this solution work ? Also, do we need an insulating material between copper strip and wire in between Aluminum body ?