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.

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
Extol receives patent for revolutionary nanoSTAKE® plastic staking technology

Extol receives patent for revolutionary nanoSTAKE® plastic staking technology

Extol is pleased to announce that we have received a patent for our revolutionary nanoSTAKE plastic staking technology. This is Extol’s second patent for a staking technology that will change the manufacturing industry. NanoSTAKE was developed to tackle the challenge of staking small plastic bosses in tight, hard-to-fit locations while being safe to use on electronics and other sensitive applications. The closed-loop process is fast and easy to use thanks to the proprietary Smart Respond™ heating system that rapidly heats and cools the punch at the tip of the module.

Get powder-based 3D printed PP parts from Extol

Get powder-based 3D printed PP parts from Extol

Powder-based 3D printed polypropylene (PP) parts are now available at Extol. The addition of PP expands Extol’s 3D printed powder-based materials, which already include PA12 and TPU.
We’ve received feedback that our powder-based 3D printed PP parts are performing with the toughness, ductility, and chemical resistance that customers expect from molded PP.

Read more blog posts.

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

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