The present teachings disclose a wire mesh heater including: a wire mesh element having a surface area including a non-contact area and a contact area along at least 50% of a wire mesh element length; a primary conductor including a slit having a contact surface, wherein the contact area contacts the contact surface to provide an electrical connection between the wire mesh element and the primary conductor. In some embodiments, the primary conductor is welded to the wire mesh element, wherein the contact area contacts the contact surface to provide an electrical connection between the wire mesh element and the primary conductor. In some embodiments, an elastic is stretched and secured tautly under tension prior to operation of the wire mesh heater, and the elastic keeps the wire mesh element tautly under tension during operation of the wire mesh heater.