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 This patented technology shines above other outdated, hot, and sticky staking processes.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.
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.
The New IS32 InfraStake Module
…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?
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.
Strong
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
Why you see flash when staking plastic and how to optimize it
The moment is here, the process is set, the machine has cycled. How does it look? “GASP!” My staked part has FLASH!!! If you are not familiar with flash, I’m referring to the displaced plastic material from a staking or welding process that extrudes outwards and does not contribute to the strength of the joint. Flash may be observed as fine dust surrounding the joint, thin strands of plastic material in a disorganized clump, or even smooth rounded material adjacent to the weld joint. So why does flash occur in plastic staking and how can you optimize stake appearance?
Why does Extol have an Integration Support division?
Why does Extol have an Integration Support division? To support integrators of innovative, Extol technology. Integration Support is a separate division of Extol that is devoted to supporting integrators. This dedicated team works with machine builders to create an integration package that will meet the end‑user’s specific needs.
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.
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.