Lee Plastics offers a variety of value-adding processes. These processes allow us to provide intricately designed plastic pieces that are pre-assembled, feature product logos and more. One of the value-adding processes we offer is fusing pieces together with heat staking and ultrasonic welding. Both of these methods allow us to fuse multiple pieces together before we ship them. However, they provide different advantages and disadvantages.
How Heat Staking & Ultrasonic Welding Work
Both heat staking and ultrasonic welding use stakes to weld two parts together. One part has a hold carved into it while another part has stakes added in the form of threaded inserts, similar to an iron screw. The threaded insert is pressed into the hole of the piece and then through either heating or ultrasonic welding is kept in place. These processes create strong joints in plastic and metal pieces that can allow dissimilar pieces to be held together long term.
Ultrasonic Welding
Throughout the history of plastic manufacturing, manufacturers have always relied on whatever method is going to create reliable and repeatable results. Ultrasonic welding provided repeatable results long term. Ultrasonic welding uses high-frequency acoustic vibrations applied locally to force to solid pieces of matter to fuse together and become welded. It can be used to join two different materials together and best rated for plastic pieces and metal components. Ultrasonic welding became one of the most popular welding options for plastic manufacturers since it first was introduced. However, heat staking has been known to make more precise welds.
Heat Staking
Heat staking is a newer form of welding two dissimilar materials together. Heat staking works by expanding a stake from one piece into a hole of another piece. The insert fills in knurls and undercuts so that the two plastic pieces become bonded together. Heat staking resists rotational torque better than ultrasonic welding does. However, heat staking can cause damage to the areas that are under pressure and are heated during the staking process. To avoid this, plastic manufacturers have to control a variety of variables to ensure that the plastic piece is not damaged during the heat staking process.
Contact Lee Plastics
Lee Plastics provides a variety of services when designing, manufacturing, and delivering plastic pieces. Our team has over 100 years of experience in the industry and would love to offer a quote on your next project.