Ultrasonic Welding Joint Designs: Download the PDF by clicking here: Ultrasonic-Welding-Joint-Designs.pdf
Heat Staking Design Guidelines: Hollow Stake:
- Works well with Large diameter studs (no smaller than .080" O.D.)
- Produces a large strong head
- Does not have to melt a large amount of material (less time, less force)
- Avoids sink marks on the opposite side of molded component
- Enables parts to be re-assembled with self-tapping screws should repair or dis-assembly be necessary
- Aesthetically pleasing (can be made to look like it was "molded" on)
Rosette/Flared High Profile:
- Recommended for large diameter posts
- Flares out material giving 360 degrees of even holding strength
- Stakes / moves more volume easily
- Slightly less staking forces required
- Slightly less cycle time as opposed to a dome stake on large studs
- Alignment to our staking heads is critical (use our X-Y adjustments)
- Requires very accurate positioning so that center point of tip contacts center of stud
- Not generally recommended for use on heated platens (best on probes) because of thermal expansion
- Not generally recommended on small diameter studs
- Aesthetically pleasing (looks like a rivet)
Knurled Stake:
- Alignment is not an important consideration from an application standpoint
- Ideally suited for high volume production
- Three styles available: fine knurl, medium knurl, coarse knurl
- Generally the pitch/texture of the knurl is related to diameter of stud to be staked
- Can knurl a large tool and hit many stakes without alignment worries
- Good use on heated platens where thermal expansion is generally a problem
- Also works well when mating component has a countersink
- Greatly reduces cycle time
Rosette Low Profile:
- Recommended for large diameter posts
- Flares out material giving 360 degrees of even holding strength
- Stakes / moves more volume easily
- Less staking forces required
- Slightly less cycle time as opposed to a dome stake on large studs
- Alignment is critical
- Requires very accurate positioning so that center point of tip contacts center of stud
- Not generally recommended for use on heated platens (best on probes) because of thermal expansion
- Not generally recommended on small diameter studs
- Aesthetically pleasing
Flush Stake:
- Used for applications requiring a flush surface
- Requires that mating component has sufficient thickness for a countersink, counterbore, or a combination of the two
- Volume of the boss is crucial to fill the countersink properly
Dome/Conical High Profile:
- Generally used with bosses with an O.D. of 250" or less
- Aesthetically pleasing
- Produces a tight stake
- Recommended for crystalline material with sharp melting points such as 33% G.F. nylon, highly defined melting temperatures, (post cooling a must)
- Good for glass filled materials, or materials with abrasive fillers
- Good for materials that degrade easily (post cooling)
- Dome stakes come in two profiles: High and Low
- High Profile stake is typically .750" high 3/4" or more
- Low Profile stake type -.375=3/8" or less
- Works well into counterbored holes
Dome/Conical Low Profile:
- Generally used with bosses with an O.D. of 250" or less
- Aesthetically pleasing
- Produces a tight stake
- Recommended for crystalline materials with sharp melting points such as 33% G.F. nylon, highly defined melting temperatures, (post cooling a must)
- Good for glass filled materials, or materials with abrasive fillers
- Good for materials that degrade easily (post cooling)
- Dome stakes come in two profiles: High and Low
- High Profile stake is typically .750" high 3/4" or more
- Low Profile stake type -.375=3/8" or less
- Works well into counterbored holes
