Watlow’s current industrial heater designs are limited by conventional manufacturing methods that restrict internal geometry and can reduce thermal performance. This project explores the use of additive manufacturing to create advanced internal heater geometries that improve flow mixing and potentially enhance heat transfer efficiency and temperature uniformity. Using CFD simulations and a custom experimental flow-testing platform, candidate designs were evaluated based on mixing effectiveness and pressure-drop performance. The results established key tradeoffs between flow enhancement and hydraulic losses, identifying promising geometries for future high-temperature testing and providing a pathway toward next-generation industrial heater designs.