When an off-the-shelf sensor fails to survive your operating environment—whether due to extreme thermal thresholds, restricted mounting geometry, aggressive process media, or obsolete OEM part numbers—a custom-engineered thermocouple is the most reliable solution.

At Kehao, we design and manufacture precision, heavy-duty custom thermocouples tailored for over 100 industrial applications globally, spanning from one-off replacement probes to high-volume OEM production runs.

Need a fast design quote? Send us a drawing, a physical sample, or a brief application description. Our engineering team will review your specs and provide a tailored design recommendation and quote within 24 to 48 hours.

Get a Quote for Your Custom Thermocouple

Why Choose a Custom Thermocouple?

Over 80% of field thermocouple failures stem from mechanical and environmental mismatches rather than incorrect calibration types. Common issues include sub-optimal sheath alloys, ungrounded junction mismatches, inadequate immersion lengths, or incompatible lead wire terminations.

Custom manufacturing eliminates these failure points by delivering:

• Seamless Legacy Replacement: Re-engineer obsolete or overpriced OEM sensors for legacy machinery without modifying existing equipment.

• Extreme-Environment Survival: Match sheath materials, internal insulation density, and junction designs to survive high vibration, vacuum environments, molten metals, and corrosive chemical processing.

• Drop-in Plug-and-Play Installation: Replicate existing threads, mounting flanges, quick-disconnect plugs, and wire harnesses to ensure zero plant rework during retrofits.

• High-Precision Temperature Control: Order Special Limits of Error (Class 1 / Special Tolerance) wire accompanied by NIST-traceable individual calibration certificates.

• Streamlined Supply Chain: Consolidate multiple sensor part numbers into a single quality-assured supplier and unified specification framework.

Customization Capabilities & Technical Specifications

Every component of our thermocouple assemblies can be tailored to meet your exact engineering requirements:

Engineering & Manufacturing Workflow

[Spec Review & DFM] ➔ [Material Selection] ➔ [Precision Welding & Compaction] ➔ [Quality Assurance] ➔ [Documentation]

1. Engineering Consultation: Our team performs a Design for Manufacturability (DFM) review on your drawings, samples, or process requirements.

2. Material Matching: High-purity MgO insulation, premium-grade thermocouple wire, and sheath alloys are matched to your specific operating parameters.

3. Precision Fabrication: Hot junctions are joined using automated TIG or Laser welding techniques. MgO-sheathed assemblies are drawn and compacted to achieve maximum dielectric strength.

4. Rigorous Quality Testing: Every unit undergoes 100% continuity checks, insulation resistance testing (at high voltage), and dimensional verification. Optional multi-point comparison furnace calibration is available upon request.

5. Certification & Delivery: Orders ship complete with material test reports (MTRs), certificates of conformance, and NIST-traceable calibration data.

OEM & Private-Label Manufacturing Services

We support equipment manufacturers and distributors with scalable private-label manufacturing:

• Private-Labeling: Custom laser-etched branding, custom part numbering, and tailored packaging.

• ODM Design Services: You supply the performance and space envelope; our engineers design the complete sensor package.

• Scalable Production: Flexible capacity designed to handle rapid prototyping through high-volume production cycles.

• Quality Compliance: Manufactured under ISO 9001 and CE certified quality management systems.

• Flexible MOQs: Low minimum order quantities for prototypes, with scalable volume pricing for recurring orders.

Frequently Asked Questions (FAQ)

What information is needed to quote a custom thermocouple?

For the fastest response, provide an engineering drawing or the original part number along with operating temperatures, media type, and termination style. If you only have basic details (e.g., temperature range and probe dimensions), our team can recommend the optimal configuration for your application.

Can you reverse-engineer a sensor from a physical sample?

Yes. You can send your worn or damaged sensor sample to our facility. We will perform dimensional analysis, identify wire alloys and junction construction, and produce a matching replacement.

What is the typical lead time for custom probes?

Prototype and evaluation quantities (1–10 pcs) typically ship in 5 to 7 business days. Standard production runs generally ship within 2 to 3 weeks, depending on material availability and testing requirements.