Case Study: Plastics Heat Staking and Welding

About Infrared Welding

For plastic parts, Infrared Welding can be a beneficial replacement for certain traditional hot-plate and vibration welding applications. The use of a controlled IR light source (heater) with accurately regulated time and temperature in a precise location allows more accurate process control on plastic assemblies.

Different heat levels for varying welding conditions can be accomplished on a single fixture. The ability to place the infrared heaters in various positions makes it possible to weld multiple surfaces in one setup. Because the infrared heat source does not touch the part, the process is cleaner. Unlike the hot-plate process, plastic does not stick to the heat source.

Production Goes Up

The downtime required to clean or remove a hot plate two or three times per shift is eliminated. With the instant-on of infrared heaters, no time is wasted waiting for tooling to heat up.

New setup changeover happens faster because you don't have to wait for tooling to cool down (as you would with hot-plate setups).

Reduced Costs

There are several cost reduction opportunities with Infrared Welding systems. Capital investment is reduced. Backup tools are not needed. An IR Welding machine takes up less floor space, and electric consumption is much less. Injection molding tooling costs can be reduced since tongue-and-groove part designs for surface joining requirements are eliminated. More consistent hermetically sealed parts result.

IR Welding Advantages

Low maintenance
No contact to part surface
Eliminates plastic sticking to tooling
Back-up tools eliminated
Instant start-up
More accurate part temperature control
Smaller machines / less floor space
Lower tool cost; tongue-and-groove not required
Hermetic sealing of parts
Replaces hot plate and vibration welding
Lower energy consumption
Non-contact process results in higher quality level

IR Heat Staking Advantages

This cost-effective method of assembling plastic components uses concentrated IR energy to focus heat on the plastic stake.

Reduce cycle time < 10 seconds
Non-contact heat
Instant on/off
Dramatically reduced compressed air consumption
Low/no maintenance due to non-contact heat method
Reduced energy costs
Focused energy eliminates heat damage to temperature sensitive areas

For more information...

Explore this site for application solutions employing this technology. Heraeus also offers complete systems. Please contact us to discuss your application.

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