What is Heat Staking?
Heat staking is a thermal assembly process used to join thermoplastic components through controlled application of heat and pressure. This technique reshapes a plastic stud or boss to mechanically secure components together without the need for adhesives, solvents, or mechanical fasteners. Heat staking is essential in applications where material integrity, structural strength, and precision are critical, such as electronic enclosures, automotive assemblies, and medical devices.
How Does It Work?
The heat staking process involves localized heating of a thermoplastic protrusion (stud or boss) using a heated tool or tip. When the plastic reaches its melting point, pressure is applied to deform it into a predefined shape—typically a rivet head. Upon cooling, the plastic solidifies, forming a permanent mechanical joint. This method allows for precise control over temperature, pressure, and dwell time, ensuring consistent and repeatable results.
Sonitek offers a range of heat staking equipment tailored to various manufacturing needs:
- Vertex mini/MAX: Our newest model featuring self-calibration, integrated temperature controls, presets, data export capabilities, and mechanical upgrades for superior accuracy and precision. Ideal for applications requiring stringent process control and traceability.
- Vertex BASIC: A compact, cost-effective thermal press equipped with user-friendly touchscreen controls and integrated system controllers. Suitable for basic applications where space and budget are considerations.
- TS-100 Series: A hand-operated press perfect for low-volume production runs and prototyping applications, offering flexibility and ease of use without sacrificing precision.
- ServoStaker: An advanced plastic joining system with precise Z-axis control, integrated temperature management, real-time monitoring, and customizable features. Designed for complex applications requiring high precision and process control.
- ULTRA Series: A feature-rich thermal press offering a wide range of options, accessories, and a multi-level control package via a color touchscreen. Expandable I/O capabilities allow integration with automation systems and process monitoring.
- High Tonnage Heat Stakers: Robust systems designed for demanding applications, delivering up to 5 tons of force with precision and durability. Suitable for large assemblies and materials requiring higher staking forces.
What Is It Suitable For?
Heat staking is suitable for a variety of applications across multiple industries:
- Electronics: Assembling circuit boards, securing components, and fastening plastic housings without introducing contaminants or risking thermal damage to sensitive parts.
- Automotive: Joining interior components, dashboards, and control panels where strong, vibration-resistant joints are necessary.
- Medical Devices: Ensuring secure assembly of components where material compatibility, sterility, and precision are critical.
- Consumer Products: Fastening components in appliances, toys, and electronics where aesthetics and structural integrity are important.
Sonitek’s Heat Staking Solutions
With over 30 years of experience in thermal assembly technologies, Sonitek provides heat staking equipment designed for seamless integration into production lines. Our machines offer precise control over key process parameters, ensuring consistent quality and repeatability. We support applications from low-volume prototyping to high-volume production, offering solutions that enhance manufacturing efficiency and product reliability.