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How to design for plastic staking

Unlock the full potential of your plastic part designs by watching our webinar, where industry experts Katherine Urivez and Sean Minch will guide you through cutting-edge technologies like InfraStake and nanoSTAKE. Download now to transform your staking designs, avoid pitfalls, and discover facts that will elevate your plastic staking expertise.

InfraStake, The Premiere IR Plastic Staking Technology

InfraStake is a clean staking process that uses focused infrared energy to heat and form a plastic boss. In this webinar, you’ll learn how InfraStake produces the tightest and strongest plastic assemblies.

Infrared plastic staking

InfraStake® is a tight, clean staking process that uses focused infrared energy to heat and form a plastic boss. This patented technology shines above other outdated, hot, and sticky staking processes.

The InfraStake Process

Reflective surfaces focus infrared energy from an IR lamp onto the plastic boss, heating it. Once the material is softened, a non-heated punch forms the boss into a stake.


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


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


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


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

The New IS32 InfraStake Module

The IS32 InfraStake module is the latest development in InfraStake technology. Coupled with our new InfraStake Integration Software, IS32…

reduces lifetime cost by reducing maintenance.

provides full quality assurance through increased process monitoring.

reduces issues in manufacturing with a more intuitive process.

InfraStake Integration Software

The InfraStake Integration Software unleashes the full power of the InfraStake process. Users can monitor the process and see the results graphically. In addition, the Processing Assistant makes everyone an InfraStake expert. Just by answering a few simple questions, an inexperienced user can optimize the InfraStake process.

The new IS32 InfraStake module delivers lower lifetime cost

The new IS32 InfraStake module is Extol’s latest development in InfraStake technology. In combination with the new InfraStake Integration Software, the new module reduces lifetime operating costs by reducing maintenance. Numerous improvements have been made which work together to make the process more time efficient and less expensive for customers.

The new InfraStake software provides full quality assurance through process monitoring

Extol has developed a new software package that controls the InfraStake process. The InfraStake Integration Software comes free with every integration package to ensure consistency across every integration of the InfraStake technology. The new IS32 module, paired with the InfraStake Integration Software, provides full quality assurance and strong stake joints by monitoring crucial process variables and graphing them for easy interpretation.

How do you measure temperature during the InfraStake process?

We often get the question, “How do you measure temperature during the InfraStake process?” The answer is, we don’t. There are a few reasons why not, but first, let’s clarify what this question is really getting at: How does the InfraStake process confirm quality results? Furthermore, can monitoring temperature during the InfraStake process guarantee a good part?

InfraStake Benefits

Tight stake joints

InfraStake modules are designed to clamp the components during the staking process. Each module clamps directly at each stake point with independent pressure to ensure the assembly is tight when the staking process is complete. A tight joint means no buzzing, squeaking, or rattling!

Quality assurance through process monitoring

InfraStake software monitors several key process variables to ensure a successful and quality stake joint. Current sensors ensure the IR energy turns on while position sensors monitor the punch to detect the proper height of the boss and depth of the completed stake.

Lower cost than ultrasonics

InfraStake is more cost effective than ultrasonic staking. The power supplies used with InfraStake are much less expensive than ultrasonic generators and each one powers up to four modules.

Safe, non-invasive staking

InfraStake does not vibrate during the staking process and the module does not get hot because the IR energy is focused only on the plastic boss. This means that it is safe to use with sensitive electronic components.


InfraStake heats up the plastic boss to a semi-molten state before staking. This allows the material to flow when it is formed and reduces any internal stresses that can occur with other processes.

No A-surface marking

InfraStake does not use excessive heat or vibrate, which greatly reduces the risk of A-surface marking.

Reliable and repeatable

InfraStake uses IR energy from a halogen lamp as the heat source. The output from this lamp is consistent and controlled by time which means the amount of energy applied to the plastic boss is the same every cycle.

Higher quality and lower energy than hot air

InfraStake produces stronger, more consistent stakes and uses less air and electricity than the hot air staking process.

Equipment Options

We offer ‘turn-key’ machines ranging from standard Extol press options to fully customized assembly machinery. Additionally, Extol provides a comprehensive package of InfraStake components and accessories to customers who build assembly equipment ‘in-house’ and to equipment integrators/machine builders.

Standard Machines

An ideal solution for staking small to medium-sized thermoplastic parts.

InfraPress 304

  • 3″ x 4″ tooling area
  • Capacity of up to 4 InfraStake modules

InfraPress 713

  • 7″ x 13″ tooling area
  • Capacity of up to 12 InfraStake modules

Custom Machines

The possibilities are endless with Extol’s custom machines. We’ve built unique single-point InfraStake machines and others incorporating 100+ InfraStake modules. Projects range from simple bench-top machines to complex work cells, which feature numerous IR machines and additional joining processes and functions.

Integration Packages

Integration packages include:

  • InfraStake modules
  • Power supply / controller
  • Air manifolds for module function
  • Dual flow rate air filtration and regulation system
  • Maintenance tool kit
  • Detailed documentation

Module Selection

There are three different InfraStake models available. Below are some of the differences between each model.

Model IS32

  • Latest InfraStake technology
  • Analog punch position sensing (+/- 0.05 mm)
  • 100 W tungsten halogen lamp
  • 32 mm diameter module
  • Max boss size: Ø9.0 x 12.7 mm

Model IS125

  • Original InfraStake technology
  • Digital punch position sensing (+/- 0.5 mm)
  • 100 W tungsten halogen lamp
  • 32 mm diameter module
  • Max boss size: Ø6.4 x 9.5 mm

Model ISM20

  • Smallest InfraStake technology
  • Digital punch position sensing (+/- 0.5 mm)
  • 35 W tungsten halogen lamp
  • 20 mm diameter module
  • Max boss size: Ø3.0 x 4.0 mm
What is the difference between plastic welding and plastic staking?

What is the difference between plastic welding and plastic staking?

If you’re an engineer, you may wonder what the difference is between plastic welding and plastic staking. Both of these methods join plastic together, but they use different techniques. Here, we’ll look at the differences between these methods so you can decide which is right for your project.

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Alternatives to Ultrasonic Welding

Alternatives to Ultrasonic Welding

If you’re familiar with plastic welding, you’ve probably encountered ultrasonic welding. It’s the most well-known plastic welding technology. But just because it’s popular, doesn’t mean it is the best choice for every application. It has many benefits, but also some drawbacks. What do you do if ultrasonic welding isn’t your best option? And how do you know?

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Request a quote for InfraStake.

Tell us about your application and request a quote. Whether you want a turnkey InfraStake machine or an integrable solution, we’ve got you covered.

Let us know what you need.