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 Welding Processes section to get the basics.

Webinars

Join the discussion on the latest in automation, additive manufacturing, welding, and assembly.

Blog

Read our blog posts about staking, laser welding, 3D printing, and much more.

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

IR Welding

IR welding is the non-contact welding process that joins two plastic parts together with IR energy. IR emitters heat a weld rib or bead on each component. The IR source is removed and the parts are pushed together until they are welded.

Technology Examples:

  • InfraGuide
  • Quartz IR
  • Metal Foil IR

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

Hybrid Vibration Welding

Two components are vibrated in shear against each other, generating heat from friction. Vibration stops and pressure is maintained while the components bond to one another. Hybrid vibration welding adds an IR preheat at the beginning of the cycle to soften the rib and reduce the amount of particulate flash generated from the vibration cycle.

Technology Examples:

  • CEMAS Vibration Welders

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
The basics of hot plate welding plastic parts

The basics of hot plate welding plastic parts

Hot plate welding is a thermoplastic joining process that uses heat and pressure to form strong, reliable welds in parts. It’s an efficient and cost-effective method for manufacturing components from plastic materials such as PP, ABS, PC, TPE, and more. Hot plate welding offers numerous advantages over other plastic joining methods, such as stronger, particulate-free welds. This guide will cover the basics of hot plate welding, including its steps, benefits, and typical applications. We will also discuss tips for designing your parts for hot plate welding success and the equipment used in this process.

read more
Top 6 Reasons Machine Builders are Switching to 3D Printing

Top 6 Reasons Machine Builders are Switching to 3D Printing

3D printing technology and materials have advanced rapidly, offering new possibilities and advantages for machine builders. Machine builders are replacing traditional CNC machining and urethane casting processes to use 3D printing for applications such as fixtures, EOAT, tricky custom details, and first shots of customer parts for debugging. Let’s explore some of the benefits of 3D printing for machine builders, focusing on design freedom, reducing lead time and cost, reducing detail count, replacing messy urethane casting, keeping debug timelines moving, and reducing weight.

read more
Which Unlocks More 3D Printing Applications? – DfAM or Business Model Innovation

Which Unlocks More 3D Printing Applications? – DfAM or Business Model Innovation

Despite the promise of Additive Manufacturing (AM), many organizations have failed to capitalize on its potential. This is partly because AM presents a unique set of challenges, which can be difficult to overcome without extensive experience and expertise. As a result, many organizations have pursued applications that are not well-suited for AM, leading to late and expensive failures. In order to maximize the benefits of AM, organizations need to invest in and deliver successful applications. With the right approach, AM has the potential to change the world.

read more
What is the difference between plastic welding and plastic staking?

What is the difference between plastic welding and plastic staking?

If you’re an engineer, you may wonder what the difference is between plastic welding and plastic staking. Both of these methods join plastic together, but they use different techniques. Here, we’ll look at the differences between these methods so you can decide which is right for your project.

read more
Extol Obtains FDA Registration to Offer Turnkey Manufacturing for 3D Printed Medical Devices

Extol Obtains FDA Registration to Offer Turnkey Manufacturing for 3D Printed Medical Devices

Michigan-based digital manufacturer, Extol, Inc., announces FDA registration for contract manufacturing of 3D printed medical devices. The FDA registration will allow Extol to expand its offerings for the life-sciences industry. It will immediately impact Extol’s capability to provide complete solutions for additive manufacturing of medical devices for the orthotics and prosthetics (O&P) market.

read more
Alternatives to Ultrasonic Welding

Alternatives to Ultrasonic Welding

If you’re familiar with plastic welding, you’ve probably encountered ultrasonic welding. It’s the most well-known plastic welding technology. But just because it’s popular, doesn’t mean it is the best choice for every application. It has many benefits, but also some drawbacks. What do you do if ultrasonic welding isn’t your best option? And how do you know?

read more

Read more blog posts.

Check out all of our blog posts about staking, laser welding, 3D printing, and more.

Ready to get started?

Tell us about your project and how we can help.

Get your plastic assembly equipment and services done your way.

Contact us.