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Component welding and heat staking

We have the technology and expertise to carry out a range of different methods for joining components together during the assembly process. The type of weld required, the materials involved and part design and complexity are all key considerations when choosing the best method for your project.

Ultrasonic welding

Ultrasonic welding applies high speed vibration that creates friction to heat and melt two plastic surfaces. Once these surfaces have cooled, the two separate components become bonded together as a single part.

Ultrasonic welding delivers a high-quality hermetic seal no matter what shape the plastic component is. It also eliminates the need for solvents or adhesives. We often use ultrasonic welding for specialised applications in the medical, electronic and automotive industries.

ultrasonic

Benefits of ultrasonic welding

Ultrasonic welding is cost-effective, efficient and reliable. Here are some other benefits:

  • A strong, virtually invisible, hermetic seal
  • No need for adhesives or solvents
  • Simplifies part design and assembly with fewer components
  • Fast and repeatable process
  • No need for fasteners which reduces weight
spin welding

Spin welding

Spin welding is used on parts that require circular joints. Our assembly technicians load one part into the machine’s spin tool which rotates while the other part remains stationary. Friction melts the surface of both parts which are held together until the material cools and the single welded part can be extracted from the machine.

Benefits of spin welding

There are many benefits to spin welding:

  • Creates a strong, reliable, hermetic seal
  • Can weld circular joints
  • Can tolerate contaminants more than ultrasonic welding
  • Suitable for most plastics
  • Can weld different types of plastic together
  • Low cost and energy efficient
  • No need for adhesives

Hot plate welding

Heated plates are used to melt the surfaces of each component which are brought together and bonded to make a single part with a strong hermetic seal.

Benefits of hot plate welding

There are many benefits to hot plate welding:

  • Can join any shape and parts with complex geometry
  • No need for solvents or adhesives
  • Creates a strong, clean joint
  • Suitable for many types of thermoplastic
  • Different chemically compatible thermoplastics can be welded together
heat_staking

Heat staking

Heat staking can be used when you need to join two different materials together such as plastic and metal. A pre-moulded boss or stud on the plastic part is inserted into a hole in the second component. This is then heated using electricity rather than friction to melt the boss which, once cooled with compressed air, locks the two parts together.

Benefits of heat staking

There are many benefits to heat staking:

  • No risk of damage from vibration
  • Can join different polymer types together simultaneously
  • Can join plastic to metal or other materials
  • Cost-effective
  • Multiple connection points can be joined simultaneously
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