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Plastic Welding Processes

Plastic welding is the process of heating up two plastic parts and bonding them together by applying pressure. There are several different welding technologies that differ in their application of heat and pressure, but the basic steps are heat, apply pressure (force), and cool. The weld created between the parts is a strong molecular bond and depending on the welding technology, is hermetically sealed. Learn more about specific joining processes below.

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

Laser Plastic Welding

Laser welding uses a precise IR laser beam that is directed through a transmissive material and penetrated into an absorptive material. The two materials are held in tight contact with each other and the joint between them heats up and melts as energy from the laser is absorbed. The result is a clean weld with minimal flash.

Technology Examples:

  • Extol configures laser welding machines around the application

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
4 Steps to Unlocking Innovation with 3D Printing

4 Steps to Unlocking Innovation with 3D Printing

3D printing a single rapid prototype is now the accepted best practice for engineering and product development. But what if you want to take the next step to create even more value? How do you find and develop successful applications for functional prototypes and production?
As volumes increase to 10’s, 100’s, and 1000’s, the cost of 3D printing can become more difficult to justify. While it may take more effort, it also has the potential for a bigger payoff. Follow these 4 steps to unlock innovation and the full potential of 3D printing.

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Hot plate welding brackets, ports, and other small components

Hot plate welding brackets, ports, and other small components

Trying to hot plate weld small brackets, or ports onto a large complex part can be tough and expensive in a standard machine. These types of applications often need a modular, configurable solution to fit around the parts. Often, the main piece has several small components, each needing a welding operation. For example, many automotive underhood ducts are long and meandering and have a couple of ports and brackets.

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Laser Plastic Welding Myths Debunked

Laser Plastic Welding Myths Debunked

There are several myths about laser plastic welding machines and their technology. Let us clear things up a bit. These are some of the top laser plastic welding myths DEBUNKED…

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Advantages of Servo-Driven Hot Plate Welders

Advantages of Servo-Driven Hot Plate Welders

Servo-controlled hot plate welders completely revolutionize the hot-plate welding process. Take it from Extol, we started the servo movement with the Rapid Conductor hot plate welder. Our welders use servo-motors to control the platens and weld strong, repeatable parts.

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