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.
Extol partners with HP to launch Digital Development Center™ for 3D printing
Extol has launched a new Digital Development Center (DDC) to provide parts and engineering support to help its customers develop high-value applications for additive manufacturing using HP Multi Jet Fusion technology.
How to determine the strength of a plastic staking joint
Design engineers often ask us, “How strong will my staked joint be?” Usually, they’re designing a plastic assembly that needs to be staked, and they need to know how to design the part so that it will be strong enough for their application. They just want a number, like 450 N. If they know how strong one stake point will be, they can plan how many stake points they need and where to locate them. The good news is that we can estimate the answer…
We are doing it again…
We are doing it again… We are redesigning nanoSTAKE. What? Why?!
Well, this is what we do. Rather than wasting a lot of time trying to develop the perfect product and coming up short or missing the mark entirely, we work hard to get a viable product in your hands fast. We want you to see it, touch it, play with it, and tell us what should improve. That way we can make it better.
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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