Hot-Plate Welding

What is 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.

Melt

Two components are brought into contact with a heated tool. The heat conducts into melt ribs causing them to soften. Also called the ‘Heat Phase’.

Open

The components are removed from the heated tool and it is retracted out of the way. Also called the ‘Changeover Phase’.

Seal

The components are brought together and a hold pressure is applied until the weld cools. Also called the ‘Weld Phase’.

Learn how to design for hot-plate welding.

A well-designed joint is critical to achieving a robust hot-plate weld. Follow our easy-to-use guidelines to optimize your part design for hot-plate welding and achieve the strongest weld possible.

Get your hot-plate welding equipment from the experts.

We’ve been hot-plate welding for more than 30 years. So, when you get your hot-plate welding equipment from Extol, you can trust us to take care of everything. We’ll help you decide whether you need one of our configurable standard hot-plate welders or a completely custom solution.

Rapid Conductor™

The most sophisticated hot-plate welder on the market featuring fully-supported, servo-driven platens for fast, powerful, and independent force and distance control.

Compact FUSION™

The smallest servo-driven hot-plate welder available. Ideal for smaller assemblies, cleanrooms, and limited-space environments.

Custom Welders

The possibilities are endless with our custom hot-plate welders. Whether you need something small and simple, or large and automated, we’ve got you covered.

Rapid Conductor

In a class of its own, the Rapid Conductor is the most precise hot-plate welder on the market. Three servo-driven platens are expertly programmed to provide accurate velocity, force, and displacement control.

This powerhouse welder is trusted by customers in diverse industries all around the globe. The Rapid Conductor’s servo-controlled hot-plate welding technology is ideal for applications that require a strong weld, a hermetic seal, and for components with complex geometries.

Rapid Conductor Benefits

Fast

Three servo-driven platens deliver fast platen motion and minimized open times resulting in a shorter cycle time.

Process Control

Servo-driven platens eliminate the need for hard-stops and provide ultimate force, velocity, and displacement control and feedback.

Flexible

Interchangeable tooling and heated tool storage options allow for a complete tooling changeover in minutes.

Intuitive

Intuitive operator interface and user-defined I/O make for easy configuration while unlocking the power of the Rapid Conductor.

Rapid Conductor Models

There are three different Rapid Conductor models available.

1015

  • 10 x 15″ heated platen working area
  • 2000 lbs maximum clamp force
  • 5 temperature control zones

1524

  • 15 x 24″ heated platen working area
  • 4000 lbs maximum clamp force
  • 7 temperature control zones

2040

  • 20 x 40″ heated platen working area
  • 6000 lbs maximum clamp force
  • 9 temperature control zones

Features

The impressive list of standard features include:

  • 3 servo-driven platens: upper and lower press platens and heated platen provide fast and precise force, velocity, and displacement control for consistent melt and seal profile.
  • On-board SPC data logging of previous 50 cycles provides an accurate history for monitoring quality.
  • (16) recipe storage capacity allows for efficient setup and adjustment of process parameters.
  • Automatic teach mode eliminates the guesswork of initial process setup.
  • Thermal expansion compensation technology maintains the centered position of heated tooling while allowing for thermal expansion.
  • User-defined I/O for tooling functions enables easy configuration of sensors and valves through the operator interface.
  • Safe-exit emergency stop routine prevents over-exposure of parts to the heated platen.
  • and more…

Additional Options

Available options include:

  • Stage II data collection package provides remote SPC data acquisition.
  • Calibration kit allows for recalibration of machine.
  • Quick-change tooling package enables faster and easier tool changes.
  • Uninterruptible power supply (UPS) with controlled shutdown mode (CSM) protects operators and machine in the event of power failure.
  • Cleanroom package meets requirements and specifications for machine to operate in a cleanroom.
  • High-acceleration press platens (Model 1015 only) provides improved material release from heated tooling after melt phase.
  • Barcode reading/processing capability allows for integration with manufacturing traceability systems.

Welding a Leather Glove Box

Welding a 3D Printed Bottle

How To Do A Tool Change

Check out all our videos on YouTube.

Compact Fusion

This versatile welder delivers precision and speed in a tight package. Compact FUSION features servo-controlled press and heated platens for exceptional force and distance control all in a small benchtop configuration.

The Compact FUSION is ideal for smaller assemblies, cleanrooms, and environments where space is limited. 

Compact FUSION Benefits

Space Efficient

Efficient benchtop design makes this the smallest servo-driven hto-plate welder on the market.

Process Control

Servo-driven platens eliminate the need for hard-stops and provide ultimate force, velocity, and displacement control and feedback.

Intuitive

Intuitive operator interface and user-defined I/O make for easy configuration while unlocking the power of the Compact FUSION.

Standard Features

The impressive list of standard features include:

  • 3 servo-driven platens: upper and lower press platens and heated platen provide fast and precise force, velocity, and displacement control for consistent melt and seal profile.
  • Coordinated press platen motion ensures consistent melt and seal profile regardless of upper and lower press toll height.
  • On-board SPC data logging of previous 50 cycles provides an accurate history for monitoring quality.
  • (16) recipe storage capacity allows for efficient setup and adjustment of process parameters.
  • Allen-Bradley CompactLogix Processor and PanelView Plus 6.5" (165 mm) color, touchscreen HMI delivers intuitive machine control.
  • English and metric units.
  • Multiple temperature control zones; Max temp: 1000° F (538° C) maintain isothermal heated tooling.
  • Heater burnout and open thermocouple monitoring halts operation in case of malfunction.
  • Safe-exit emergency stop routine prevents over-exposure of parts to the heated platen.
  • Lighting inside machine illuminates internal working area.

Additional Options

Available options include:

  • Stage II data collection package provides remote SPC data acquisition.
  • Adjustable height machine base for ergonomic operation.
  • Large 12" HMI for increased visibility of operator interface.
  • Integrated load cells provides improved force monitoring through the cycle with closed-loop feedback to the controller.
  • Integrated optical linear scales provides press-platens position feedback through the cycle.
  • Back-up power supply to maintain control power for safety (not operation) during power outage.

Custom Hot-Plate Welders

With a custom hot-plate welder, the possibilities are endless. We design a solution around your application to meet your specific needs.

Here are a few examples:

  • Automated part loading and unloading
  • Welding multiple components simultaneously
  • Pneumatic platen control
  • Part inspection before, after, or during welding
  • Automated tool change
  • And much more… seriously.

Welding Several Tubes at Once

Welding a Rear Deck Lid

Hot-Plate Welding Examples

Check out all our videos on YouTube.

Learn more about hot-plate welding from our blog.

Hot plate welding brackets, ports, and other small components

Hot plate welding brackets, ports, and other small components

Trying to hot plate weld small brackets, or ports onto a large complex part can be tough and expensive in a standard machine. These types of applications often need a modular, configurable solution to fit around the parts. Often, the main piece has several small components, each needing a welding operation. For example, many automotive underhood ducts are long and meandering and have a couple of ports and brackets.

read more
Advantages of Servo-Driven Hot Plate Welders

Advantages of Servo-Driven Hot Plate Welders

Servo-controlled hot plate welders completely revolutionize the hot-plate welding process. Take it from Extol, we started the servo movement with the Rapid Conductor hot plate welder. Our welders use servo-motors to control the platens and weld strong, repeatable parts.

read more
Start Monitoring Melt Force to Improve Your Hot-Plate Welding Process

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.

read more

Request a quote for a hot-plate welder.

Tell us about your application and request a quote. Whether you want a Rapid Conductor, a Compact FUSION or a custom hot-plate welding solution, we’ve got you covered.

Let us know what you need.