Dreamings only: Consider possibility of options that insulate wire electrically (just) & place a thermally insulating layer outside the NiCr so preferred heat paths are inwards. IF you can control max temp rise well then various thermally conductive coatings may work. (eg thermally conductive epoxies - probably loaed with metal powders -=3D electrical conductivity may be good or poor depending on loading. --=20 http://www.piclist.com/techref/piclist PIC/SX FAQ & list archive View/change your membership options at http://mailman.mit.edu/mailman/listinfo/piclist .