Induction Heat Staking

Our expertise in developing metal-to-plastic bonding solutions has been applied by automotive manufacturers worldwide as they reduce weight, noise, and costs while improving fuel economy.

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Induction Heat Staking

Our expertise in developing metal-to-plastic bonding solutions has been applied by automotive manufacturers worldwide as they reduce weight, noise, and costs while improving fuel economy.

Contact Us

Induction heat-staking Benefits 

  • Meets tight production tolerances with precise localized heat to small areas creating pinpoint accuracy

  • Increases production rates with faster heating cycles

  • Reduces defect rates with repeatable, reliable heat

  • Eliminates variability from operator-to-operator, shift-to-shift

  • Maintains metallurgical characteristics of the individual metals

staking benefits

Get Your Free Induction heat-staking Application Notes

Click to read how the efficiency, effectiveness, and safety of your heat-staking process can be improved with induction.

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Heating Steel Inserts for Metal-to-Plastic InsertionHeating Steel Inserts for Metal-to-Plastic Insertion

It took 5 seconds with a 2 kW EASYHEAT to reach temperature, which melted the plastic for a solid bond without cracking the molded plastic.

Heating four brass inserts prior to insertion into a plastic motor housingHeating four brass inserts prior to insertion into a plastic motor housing

Using induction heating, the parts came to the required temperature in just 15 seconds in a highly repeatable heating method and a coil plate could offer protection against operator movement/errors

Heating stainless steel inserts for an insertion applicationHeating stainless steel inserts for an insertion application

Induction offers dramatically faster heating when compared to ultrasonics; faster heating means there is the potential to dramatically increase production rates with a highly repeatable and easy-to integrate processes.

Heating brass inserts for metal-to-plastic insertionHeating brass inserts for metal-to-plastic insertion

Innovation: Ambrell's Applications Lab was able to solve a problem that a competitor couldn't solve, which is a key benefit when purchasing induction solutions from Ambrell

Bonding plastic handles onto metal broomsBonding plastic handles onto metal brooms

With a more reliable induction heating system, they will not have to worry about lost production due to power supply issues that come with an unreliable system

Metal-to-plastic insertion of threaded magnetic steel insertsMetal-to-plastic insertion of threaded magnetic steel inserts

Outdated equipment and poor responsiveness drove this customer to a new vendor who could help them with new or improved processes for new or enhanced solutions

De-bonding a magnetic steel paint can lidDe-bonding a magnetic steel paint can lid

Induction is used to bond the device sheath to collet. Innovative coil design lifts production rate.

Heat a steel shaft for metal-to-plastic insertionHeat a steel shaft for metal-to-plastic insertion

Induction heating provides hands-free heating that involves no operator skill for manufacturing, even distribution of heating and localized application of energy limits temperature drift

Inserting brass bushing into plastic wire connectorInserting brass bushing into plastic wire connector

A three turn helical coil is used to heat the brass bushing. The brass bushing is heated for 2 seconds and then placed on the wire connector & pressed into position.

Heating magnetic steel for insertion into polypropylene for pallet manufacturingHeating magnetic steel for insertion into polypropylene for pallet manufacturing

Induction heating provides 'greener' manufacturing of pallets using reusable, recyclable materials, hands-free heating that involves minimal operator skill for manufacturing and even distribution of heating

Inserting threaded brass parts into plastic thermostat housingInserting threaded brass parts into plastic thermostat housing

This application has three different coils for varying hole patterns. A three turn oblong coil is used to heat 2 brass inserts in close proximity.

Inserting a piston stop with o-ring into an oil pump assemblyInserting a piston stop with o-ring into an oil pump assembly

Induction heating provides increased production speed, simpler tooling for customer, hands-free heating that involves no operator skill for manufacturing

Bonding of electric motor shaft to nylon face fanBonding of electric motor shaft to nylon face fan

Induction heating provides hands-free heating that involves no operator skill for manufacturing, only the metal shaft is heated so the motor is not affected, increased production due to rapid heating, decreased failure rate, originally used glue which ran into motor and caused failure and stronger bond

Heating Four Inserts SimultaneouslyHeating Four Inserts Simultaneously

The brass inserts are to be heated prior to insertion into a plastic automotive sub assembly

Brass InsertsBrass Inserts

Heating is to be accomplished within 5 seconds, and can be done in a helical coil since pick and place manufacturing is employed.

Plastic Lawn ChairsPlastic Lawn Chairs

To heat internally threaded steel inserts to a temperature above 650F for insertion into plastic lawn chair assemblies.

Brassiere UnderwireBrassiere Underwire

To heat the ends of 0.072-inch spring wire, spaced 1/2 inch apart, uniformly for the application of nylon powder on a 1inch length of the end.

Inserting Steel Studs into a Plastic Tail LightInserting Steel Studs into a Plastic Tail Light

To heat threaded steel studs for insertion into a plastic tail-light assembly at 450°F.

Heat Staking Basic Design Guidelines

Thermoplastics will flow at elevated temperatures and the solidified polymer can be re-heated to re-flow around the insert. Thermosetting polymers, once the shape has been cast, will no longer melt or flow on reheating. Table 1 shows some typical temperatures, time and power required for different materials, as established in the Ambrell Applications Lab.

The diameter of the insert hole must be the correct size to allow the plastic to flow around the insert. If the hole is too small,extra plastic will be displaced. This displaced plastic is commonly called ‘flash.’ Excessive heat and pressure may also cause flash. If the hole is too large, not enough plastic will flow into the fins and knurls to achieve the desired holding strength.

10 Induction Heating Application Notes

Induction Heating Volume 1

We have collected these 10 popular Application Notes to help you understand the many ways induction heating can improve your heating processes.

Popular heat-staking Video

Induction heat-staking Resources:

Select from our libraries of materials to help you better understand the benefits heat-staking with induction heating can bring to your process.

Four Ways To Contact Ambrell for Support

AMBRELL CORPORATION

1655 Lyell Avenue
Rochester, NY 14606
United States
 

Directions to Ambrell Corporation Directions

T: +1 585 889 9000

F: +1 585 889 4030

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AMBRELL B.V.

Holtersweg 1
7556 BS Hengelo
The Netherlands
 

Directions to Ambrell B. V. Directions

T: +31 880 150 100

F: +31 546 788 154

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AMBRELL Ltd.

Unit 6, Space Business Centre
Tewkesbury Road
Cheltenham, GLOS, GL51 9FL
United Kingdom

Directions to Ambrell Ltd.Directions

T: +44 1242 514 042

F: +31 546 788 154

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