Staking

What is plastic 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.

Benefits

The process has many benefits. It’s quick and inexpensive, eliminates fasteners, and can join dissimilar materials.

Staking Technologies

There are many types of plastic staking methods. At Extol we’ve developed two proprietary staking technologies that offer benefits over other options: InfraStake® and nanoSTAKE®.

InfraStake

InfraStake uses focused infrared light to radially heat the plastic boss. Then a non-heated punch forms the boss into a stake.

nanoSTAKE

NanoSTAKE uses Smart Respond™ heating technology to rapidly heat and cool a punch to stake the plastic boss.

Need design help?

Check out our staking design guidelines.

In addition to InfraStake and nanoSTAKE, there are other staking methods. Here’s a comparison of a few…

InfraStake

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

Benefits

  • Tight stake joints
  • Strong stakes
  • High quality
  • No sticking
  • No A-surface marking
  • Safe with sensitive components

nanoSTAKE

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

Benefits

  • Closed-loop control
  • Fits in tight spaces
  • High quality
  • No sticking
  • Safe with sensitive components

Hot Air Cold Punch

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

Benefits

  • Low cost

Drawbacks

  • High energy use
  • Low quality

Ultrasonic

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

Benefits

  • Fast cycle times

Drawbacks

  • A-surface marking
  • Damage to sensitive components

Hot Punch

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

Benefits

  • Low cost

Drawbacks

  • Sticking
  • Low quality

Let us guide you to the best staking solution

COLLABORATE – At Extol, we work with you to gain a deep understanding of the needs of your specific application.

DESIGN – We help you design your parts for the best results with plastic staking. Not only do we provide guidelines to get you started, but we review your design and provide specific recommendations. Beyond that, we validate your design by welding and testing the assembly with equipment in our lab.

CONFIGURE – Using what we’ve learned about you and your application, we help you select a staking technology. From there we configure a solution that is perfect for your needs.

DELIVER – We design, build, and deliver your plastic staking equipment. But we don’t stop there. Our exceptional team supports you from launch through the life of the program.

InfraStake

Learn more about the InfraStake technology and see if it is right for your application.

nanoSTAKE

Learn more about the nanoSTAKE technology and see if it is right for your application.

Get in touch

Talk with an expert about your application and let us guide you to the best solution that meets your needs.