a hot runner component for heating and directing fluid material of a melt stream to a mold cavity is provided . the hot runner component includes a body having a fluid passageway therein for conveying the melt stream and a heater for heating the melt stream as the melt stream passes through the fluid passageway of the body . the heater includes a core arranged in surrounding relation to the fluid passageway of the body , a thermally - sprayed dielectric substrate layer on the core and a thermally - sprayed electrical resistance element layer overlying the dielectric substrate layer . the resistance element layer forms a discrete pattern . the heater further includes a thermally sprayed dielectric overlay layer that overlies a substantial portion of the resistance element layer .