Applications Lab

An extension of your engineering team

Leak Testing and Burst Testing

Prototype Part Builds

Joint Strength Testing

6-axis Robots

Microscopic Analysis

Customers consider the work we perform in the Applications Lab as a key and highly valued service.

We have the capability to assess application feasibility over a wide variety of process methods. We also provide application-specific design recommendations for the most robust joining solution. The equipment in our lab supports preliminary and prototype assembly with in-house verification methods such as tensile strength testing, microstructure analysis, and burst and leak testing.

Feasibility Testing

At Extol, we realize how important it is for our customers to have a robust, feasible process to assemble their components. That’s why we have equipped our lab to offer the best in feasiblity testing. We are with you from the very start. From the initial design work, we provide practical guidelines and recommendations for the best joint design. Once the first parts have come off the line, we can perform testing on any of our various plastics joining equipment in the lab. From 6-axis robots with InfraStake modules to servo-driven Rapid Conductor hot-plate welders and Vortex PRECEDENCE spin welders. After joining the assembly with our plastics joining equipment, we can provide strength testing in the form of a tensile, drop, or burst test. We can also test for a hermetic seal with a visual underwater leak test. If you have a special request, just ask us. We’ll do our best to provide you with the solution you need for your plastics joining application.

Prototype and Pre-Production Part Runs

In addition to proving the feasibility of your plastics joining application, we can also perform prototype and preliminary part runs to meet any pre-production part requirements that you may have. Part runs are a big part of what we do here in the lab. We can assemble parts using our Rapid Conductor hot-plate welder, our Vortex PRECEDENCE spin welder, and our InfraStake or InfraWeld modules.

Microstructure Analysis

A microstructure analysis can be very useful in understanding what makes a weld a good one for your application. Using a microtome, we are able to cut very thin sections from a weld joint. This sample is placed under a microscope for analysis. In the example, you can see both the heat affected zone and the weld line.

Burst and Leak Testing

In the lab, we have a burst and leak test station that we use to evaluate welded parts for both strength and hermetic seal. By having the ability to test parts right after they have been welded, we are can more efficiently work with you to develop the process parameters that work best with your application.

Tensile Testing

The lab contains a tensile tester that provides uniaxial tension. The forces being applied to a component increase as the jaws of the tester separate. This continues until the part fails (fractures, breaks). Using a load cell, we can record the maximum force that was experienced by the component. This is called the tensile strength of the assembly. This strength can be compared to the strength of the parent material. This tells us just how strong the joint actually is. In plastics joining, joint strengths that are 80-100% of the parent material strength are common.

Lab Equipment

Plastics Joining Equipment

  • InfraStake and InfraWeld press
  • InfraStake modules
  • InfraWeld modules
  • Vortex PRECEDENCE spin welder
  • Rapid Conductor hot-plate welders
  • 6-axis robots
  • Ultrasonic welding press
  • Hand-held ultrasonic welding unit
  • Thermal punch press
  • Hot air, cold form modules

Measurement Equipment

  • Burst and leak tester
  • Tensile tester
  • Microscope
  • Microtome machine

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