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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
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
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.
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.
New Enhanced Lamp Improves Performance of ISM20 InfraStake
In the InfraStake process, infrared energy comes from a tungsten halogen lamp inside the module. Reflective surfaces inside the module focus the IR energy from the lamp onto a plastic boss to heat it prior to staking. So, the output of the lamp is an important factor in the InfraStake process.
3 spin welding design mistakes to avoid
Spin welding is a pretty straightforward process. You spin one plastic component against another and the friction between them causes the material in the weld joint to melt. Even with a welding process this simple, it’s easy to make design mistakes that will cause headaches later. Here are three common mistakes that you should always avoid.
Service beyond the machine
Mark recalled seeing a demo of Extol’s InfraStake technology a few months prior and was drawn to InfraStake’s built-in clamping feature that ensures tight stakes. Mark was hopeful that InfraStake would be a good fit for the door panel line, but wanted confirmation that the technology could meet the cycle time, strength, and assembly tightness requirements. That’s when our Applications Lab, the first of Extol’s wide array of customer-supporting service groups, stepped in to help.
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