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 This patented technology shines above other outdated, hot, and sticky staking processes.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.
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.
Benefits of InfraStake
Strongest Stake Joints
InfraStake softens the boss before staking, which allows the material to flow easily and minimizes internal stresses that are common with other processes.
Tightest Stake Joints
InfraStake modules clamp each stake point directly, applying independent pressure, which ensures the joint is as tight as possible.
Reliable and Repeatable
Safe for Electronics
InfraStake doesn’t vibrate, and the energy is contained, which makes it safe to use with electronics and other sensitive components.
No Sticking
InfraStake heats the boss without touching it and forms it with a non-heated punch, so it doesn’t stick to even the most challenging materials, like nylon.
Low Energy Use
InfraStake uses a low-wattage bulb, using very little energy.
No Read Through
InfraStake does not use excessive heat or vibration, eliminating the risk of A-surface marking and read-through on aesthetic components.
Tamper Evident
InfraStake produces a permanent joint that shows evidence of tampering if the product is opened. In contrast, screws can be removed without evidence of tampering.
IS32 InfraStake Module Overview
The IS32 InfraStake module is the latest development in InfraStake technology. Coupled with our 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 InfraStake software provides full quality assurance through process monitoring
How do you measure temperature during the InfraStake process?
Equipment Options
We offer turn-key machines ranging from standard Extol press options to fully customized automation equipment. 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.
404 Benchtop Staking Machine
- 16″ x 10″ 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?
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.
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.
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.