Staking

What is staking?

Plastic staking is a method of joining components together that uses a molded stud or boss to mechanically retain a mating component. Heat is applied to the boss, softening it. A forming tool is then used to reshape the material into a cap or stake.

Need design help?

Check out our staking design guidelines.

INFRASTAKENANOSTAKE

There are many types of plastic staking technologies. They vary in their application of heat and pressure, but the general concept is the same, form a plastic boss or stud into a stake to retain a mating component. Here are a few of the different staking technologies available.

nanoSTAKE

Revolutionary staking process that uses Smart Respond™ heating technology to rapidly heat and cool a punch to stake plastic.

InfraStake

Focused infrared light radially heats the plastic boss and a non-heated punch forms the stake.

Hot Air Cold Punch

Heated air softens the plastic boss and a non-heated punch forms the stake.

Ultrasonic

Metal tool (sonotrode) vibrates against the plastic boss generating frictional heat to melt it and form a stake.

Thermal Punch

Heated metal forming tool melts and forms the plastic boss into a stake.

The InfraStake Process

Clamp

Module is positioned over the molded boss. The face of the concentrator clamps the part directly at the stake point.

Heat

Infrared (IR) lamp is illuminated. Light is focused radially on the plastic boss.

Form

IR lamp is switched off and the non-heated punch forms the semi-molten boss into a stake.

Retract

After the plastic has re-solidified, the punch retracts and the module retracts from the part.

Read our blog posts about InfraStake.

New Enhanced Lamp Improves Performance of ISM20 InfraStake

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.

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Service beyond the machine

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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Learn more about InfraStake.

The nanoSTAKE Process

Heat

The Smart Respond™ heating technology heats the punch to a programmed melt temperature in seconds.

Form

The low-current, high-performance heater maintains melt temperature as the punch forms the boss into a stake.

Cool

Once the punch reaches the correct height, it rapidly cools to a programmed release temperature.

Retract

The cooled module retracts with no sticking.

Read our blog posts about nanoSTAKE.

Getting nanoSTAKE on your next project

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.

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Learn more about nanoSTAKE.

The Hot Air Cold Punch Process

Heat

Air passes through a heater and is directed at the boss.

Form

Hot air shuts off and a non-heated forming tool forms the semi-molten boss into a stake. Cooling air passes through the module to cool the stake.

Retract

After the plastic has re-solidified, the forming tool retracts.

The Ultrasonic Staking Process

Heat

A metal tool (sonotrode) vibrates against the boss generating frictional heat.

Form

As the plastic melts, the sonotrode forms the boss into a stake.

Cool

Vibration stops and the sonotrode continues to apply pressure to the stake while it cools.

Retract

After the plastic has re-solidified, the sonotrode retracts.

The Thermal Punch Process

Heat

A hot metal forming tool applies pressure and conducts heat into the boss.

Form

As the plastic melts the hot tool forms the boss into a stake.

Cool

Cooling air is directed at the forming tool, lowering its temperature.

Retract

After the plastic has re-solidified, the forming tool retracts.

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