Learning Center

Explore our Learning Center to learn more about welding and assembly processes. Read blog posts filled with helpful tips and information about automation and plastics joining technologies. Or start with the Plastic Joining Processes section to get the basics.

Getting nanoSTAKE on your next project

So, you’ve seen the new revolutionary nanoSTAKE technology and you are wondering how you can get it on your next plastic staking application. There are two great ways to do that. You can purchase a turnkey nanoSTAKE machine directly from Extol, or you can purchase nanoSTAKE through your preferred integrator. Either way, you get expert technology service from our knowledgeable team. Let’s talk more about what is included in a nanoSTAKE integration package and how they work.

Start monitoring melt force to improve your hot-plate welding process

If you do any hot-plate welding, you should start monitoring melt force to improve your weld consistency and quality. Extol’s Rapid Conductor hot-plate welder is equipped standard with three servo-driven platens: the upper and lower press platens, and the heated platen. Servo control eliminates the need for hard stops and ensures that all the pressure applied by the welder goes directly into the components being welded. It also allows the machine to control and monitor the forces throughout the process. Being able to measure the melt and seal forces means you can quickly detect and correct issues.

New Enhanced Lamp Improves Performance of ISM20 InfraStake

Extol has recently introduced a new lamp for the ISM20 InfraStake module. This lamp is 35 W, like its predecessor, but the output is enhanced to provide shorter heat times for a faster InfraStake process. Comparison testing of the new lamp showed a notable reduction in the heat time required to stake a variety of plastic materials and colors.

Read more blog posts.

Check out all of our blog posts about staking, hot-plate welding, hybrid vibration welding, and more.

Plastic Joining Processes

Staking

Plastic staking is a method of joining components together using a molded stud or boss to mechanically retain a mating component. Heat is applied to the boss, softening it, and a forming tool is used to reshape the material into a cap or stake.

Technology Examples:

  • nanoSTAKE
  • InfraStake
  • Ultrasonic Staking
  • Hot-Air Staking

Hot-Plate Welding

Hot-plate welding is the process of welding two plastic parts together using a heated tooling plate. A weld rib or bead on each component is brought into contact with the hot plate. Heat conducts into the weld rib causing it to melt. The heated tool is then removed and the parts are pushed together until they bond to one another.

Technology Examples:

  • Rapid Conductor
  • Compact FUSION

Hybrid & Standard Vibration Welding

Vibration welding is the process of welding two plastic parts together using linear vibration. A weld rib or bead on one component is vibrated in shear against another component. Heat is generated from friction causing the weld rib to melt. Vibration is stopped and the parts are clamped together until they bond to one another.

Hybrid vibration welding adds an infrared (IR) preheat to the beginning of the cycle to soften the rib and reduce the amount of particulate flash generated from the vibration cycle.

Technology Examples:

  • CEMAS 901, 902, 911, 912, 918, 950, 999

Spin Welding

Spin welding is a method of joining plastic components together with surface friction concentrated in a circular weld joint. One part is spun relative to another and force is applied, causing the material to heat and melt. The spinning process stops and the parts continue to be pressed together while they bond together.

Technology Example:

  • Vortex PRECEDENCE

Through-Transmission IR Welding

Innovative through-transmission infrared welding in a compact package. This technology uses focused IR light energy to replace adhesives. Useful in both linear and spot welding applications.

Technology Examples:

  • InfraWeld

Ultrasonic Welding

Ultrasonic welding uses high-frequency vibration to melt and weld plastic. A tool vibrates at ultrasonic frequencies and causes concentrated molecular vibration in the weld joint. The friction between the molecules heats and melts the plastic. Once the vibration is stopped, the tool maintains a holding pressure on the joint to create a bond.

Technology Examples:

  • Dukane Ultrasonics
  • Branson Ultrasonics
  • Herrmann Ultrasonics

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