Case Studies
Enhancing Production Efficiency: Achieving 1,300 Parts Per Hour in Fluid Container Assembly
This case study highlights a successful partnership between Extol and a life sciences client in developing a fully automated assembly line for a fluid container used in patient therapy. Leveraging Extol’s expertise in plastic welding and automation, the project progressed from initial design validation to high-volume production in a cleanroom environment, resulting in a rotary dial machine capable of producing 1,300 parts per hour.
Download our Plastic Welding Decision Matrix
Use this decision matrix to discover which plastic welding and staking processes may be options for your application.
Blog posts about plastic welding and plastic staking
What is the difference between plastic welding and plastic staking?
When designing a plastic assembly, one of the earliest and most important decisions engineers face is how the parts will be joined. Two of the most common options are plastic welding and plastic staking. While both methods are widely used, they serve very different purposes and lead to different outcomes in terms of strength, appearance, cost, and performance.
If you’re evaluating plastic joining methods early in your design process, understanding the difference between plastic welding and plastic staking can help you avoid costly redesigns and manufacturing challenges later on.
InfraStake: The Solution for Strong, Reliable Plastic Assemblies
In the world of plastic assembly, finding a solution that balances high strength, aesthetic quality, and process repeatability can be a challenge. Traditional methods like ultrasonic welding or hot-air staking often come with trade-offs, such as material stringing, vibration damage to sensitive electronics, or inconsistent joint tightness.
InfraStake® represents a shift in plastic staking technology. By utilizing infrared (IR) energy to precisely melt plastic bosses, it provides a mechanical joint that is as strong as it is visually clean. Here is a breakdown of how the technology works and why it is becoming the preferred choice for complex manufacturing applications.
The Ultimate Plastic Welding Webinar
Plastic welding is a key technique used across various industries to bond plastic parts easily and effectively. It’s crucial to understand the different methods available, such as hot plate welding, laser welding, and ultrasonic welding, along with their pros and cons. This overview explains these technologies, highlighting what makes each one unique and how they can be applied, while also addressing common questions to help you make smarter manufacturing decisions.
New 14mm Aperture Concentrator for InfraStake: Improved Fit and Performance
We’re pleased to announce the release of our IS32 14 mm Aperture Concentrator, designed to provide greater flexibility and performance for InfraStake applications—especially in tight spaces.
Hot-Plate vs IR Welding: The Epic Showdown
Hot plate and IR welding both require heat and pressure but differ in application methods, material compatibility, and energy consumption. Discover their unique advantages and ideal applications.
You Can’t Touch This: Non-Contact IR Welding for Plastic Parts
This webinar from Extol provides key information on non-contact IR welding for plastic parts, covering various IR sources and their energy control methods, different welding processes, material and design considerations, and applications.
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