The invention relates to a laminated fabric heater element, heater and a process for manufacturing the heater element and heater. The heater comprises an electrically conductive fabric layer attached to bus bars, is sandwiched between two thermoplastic films forming a heater assembly. In the process making the heater element or heater, the layers of the heater assembly by consolidating the layers of films and fabric into a single sheet heater without the use of adhesive resins. The heater can be made of variable geometry, electrical supply voltage and power, and can withstand more mechanical, chemical, ultraviolet radiation and other environmental stresses than prior art heaters.