Plastic Welding
What is plastic welding?
Plastic welding is the process of heating two pieces of plastic and pressing them together until they fuse. There are several different types of plastic welding. Each technology differs in how they apply heat and pressure to the parts, but the basic steps are the same — add heat, apply pressure, and cool. Plastic welds are strong molecular bonds. Depending on which welding technology is used, the weld is hermetically sealed.
Download our Plastic Welding Decision Matrix
Use this decision matrix to discover which plastic welding and staking processes may be options for your application.
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Now offering the Titan Series base system with configurable heat sources—Hot plate, InfraGuide, or Quartz IR. Titan delivers long-term flexibility without multiple dedicated machines.
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:
- Titan Series
- Rapid Conductor
- Compact FUSION
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:
- Titan Series
- InfraGuide
- Quartz IR
- Metal Foil IR
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
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
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 Eminence
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:
- InfraGuide
- 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:
- Sonics & Materials
- Telsonic Ultrasonics
Download our Material Compatibility Chart
Use this compatibility chart as a general guideline to discover which plastic materials may be options for your application. We also recommend testing to validate compatibility.
Blog posts about plastic welding and plastic staking
What is the difference between plastic welding and plastic staking?
When designing a plastic assembly, one of the earliest and most important decisions engineers face is how the parts will be joined. Two of the most common options are plastic welding and plastic staking. While both methods are widely used, they serve very different purposes and lead to different outcomes in terms of strength, appearance, cost, and performance.
If you’re evaluating plastic joining methods early in your design process, understanding the difference between plastic welding and plastic staking can help you avoid costly redesigns and manufacturing challenges later on.
InfraStake: The Solution for Strong, Reliable Plastic Assemblies
In the world of plastic assembly, finding a solution that balances high strength, aesthetic quality, and process repeatability can be a challenge. Traditional methods like ultrasonic welding or hot-air staking often come with trade-offs, such as material stringing, vibration damage to sensitive electronics, or inconsistent joint tightness.
InfraStake® represents a shift in plastic staking technology. By utilizing infrared (IR) energy to precisely melt plastic bosses, it provides a mechanical joint that is as strong as it is visually clean. Here is a breakdown of how the technology works and why it is becoming the preferred choice for complex manufacturing applications.
The Ultimate Plastic Welding Webinar
Plastic welding is a key technique used across various industries to bond plastic parts easily and effectively. It’s crucial to understand the different methods available, such as hot plate welding, laser welding, and ultrasonic welding, along with their pros and cons. This overview explains these technologies, highlighting what makes each one unique and how they can be applied, while also addressing common questions to help you make smarter manufacturing decisions.
New 14mm Aperture Concentrator for InfraStake: Improved Fit and Performance
We’re pleased to announce the release of our IS32 14 mm Aperture Concentrator, designed to provide greater flexibility and performance for InfraStake applications—especially in tight spaces.
Hot-Plate vs IR Welding: The Epic Showdown
Hot plate and IR welding both require heat and pressure but differ in application methods, material compatibility, and energy consumption. Discover their unique advantages and ideal applications.
You Can’t Touch This: Non-Contact IR Welding for Plastic Parts
This webinar from Extol provides key information on non-contact IR welding for plastic parts, covering various IR sources and their energy control methods, different welding processes, material and design considerations, and applications.
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