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 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.