- Home
- Applications
- Staking
Page contents: Control | Application Notes | Heat Staking Basic Design | Popular Video & Note | Resources
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

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.
To search all heat-staking notes, Ctrl+F keyword or ⌘+F keyword or scroll
Heating 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 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 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 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 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 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Outdated equipment and poor responsiveness drove this customer to a new vendor who could help them with new or improved processes for new or enhanced solutions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 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 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 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 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 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 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 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 Simultaneously
The brass inserts are to be heated prior to insertion into a plastic automotive sub assembly
Heating is to be accomplished within 5 seconds, and can be done in a helical coil since pick and place manufacturing is employed.
To heat internally threaded steel inserts to a temperature above 650F for insertion into plastic lawn chair assemblies.
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 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.
Our Induction heat-staking Systems and Equipment
Four Ways To Contact Ambrell for Support
AMBRELL CORPORATION
1655 Lyell Avenue
Rochester, NY 14606
United States
F: +1 585 889 4030
AMBRELL B.V.
Holtersweg 1
7556 BS Hengelo
The Netherlands
AMBRELL Ltd.
Unit 6, Space Business Centre
Tewkesbury Road
Cheltenham, GLOS, GL51 9FL
United Kingdom
F: +31 546 788 154