A barrel for a hair styling appliance includes an external surface and a heater-mounting surface inside the barrel. The heater-mounting surface is integrally formed with the external surface, and the barrel may be formed as a single extruded metal component. A barrel assembly includes the barrel, and one or more heater elements mounted on the heater-mounting surface. A hair styling appliance, such as a curling tong, curling wand or hot iron brush includes the barrel assembly. A heater element for a hair styling appliance includes a substrate having a conductive track for generating heat upon application of an electrical current thereto, and an integral temperature sensor. Manufacturing methods are used for making the barrel, barrel assembly, hair styling appliance, and heater element.

A hair styling device is described, having first and second members that are movable relative to one another between a closed operative condition and an open inoperative condition. The first member has a first heating panel and the second member has a second heating panel, the heating panels being adapted to heat a length of hair as the length of hair moves along a heating path therebetween in use, and being spaced apart in the operative condition to avoid pressing or clamping the hair therebetween. The first member also has a first pressing panel and the second member has a second pressing panel. The pressing panels are substantially planar. The length of hair moves along a pressing path between the first and second pressing panels in use. The length of the heating path is greater than the length of the pressing path.