Ultrasonic Welding vs Heat Staking

In the manufacturing industry, joining two pieces of plastic is a frequently required process. It is difficult to decide whether to choose ultrasonic welding or heat staking technology. Now, we will make a comparative analysis of these two welding processes from the following aspects, and combine your industry needs to determine the appropriate welding method for you.

1.  Two welding technology introductions;
2. Advantages and disadvantages of ultrasonic welding of plastics;
3. Advantages and disadvantages of heat staking welding plastics;
4. The difference between the two welding methods.

Ultrasonic Welding

Ultrasonic welding is the process of permanently welding two plastic workpieces using vibration and pressure. The high frequency vibration energy emitted by the ultrasonic system (ultrasonic generator box, ultrasonic transducer, ultrasonic booster, ultrasonic horn ) is transmitted to the surface of the workpieces, making them generate heat and melt, and under pressure, the two workpieces are fused together. Ultrasonic welding is commonly used in industries such as automotive, medical, electronics, food, and home appliances.

Ultrasonic Welding vs heat staking1
Ultrasonic Welding advantages vs heat staking

Advantages and disadvantages of ultrasonic welding

In terms of plastic welding, ultrasonic welding is with high strength, fast, good sealing, relatively low cost, clean and pollution-free, will not damage the workpiece, the whole welding process is very stable, and welding parameters can be tracked and controlled in the operating system.
However, ultrasonic welding cannot weld all plastics(plastics that can be welded by ultrasonic welding), which is the biggest limitation of ultrasonic welding. Regarding whether your plastic products can be welded with ultrasonic technology, you can consult our experts to help you analyze and determine the feasibility.

Heat Staking

Heat staking is the process of permanently welding two workpieces using heat and pressure. It relies on the precise control and application of temperature and pressure to cause the reforming of the plastic. To use a hot staking machine, thermoplastic material must be used for at least one of the joints part. This acts as a malleable part where heat and pressure are applied. Heat staking machine can heat the plastic to the glass transition temperature and easily weld the metal and plastic together after cooling Hot staking is commonly used in industries such as automotive, and telecommunications.

heat staking machine

Advantages and disadvantages of heat staking

Heat staking can join similar and dissimilar materials without vibration throughout the process, for example, ordinary polymers and other metals can be fused together through heat staking, and localized heating ensures that adjacent materials are not damaged, which is repeatable, economical, and safe. However, temperature control in the welding process is a major difficulty. If the control is not good, it will cause poor processing of the workpiece. Moreover, the welding time and cooling time of heat staking will be relatively longer.

Ultrasonic Welding and Heat Staking

Differences between ultrasonic welding and heat staking:

Ultrasonic WeldingHeat Staking
PrincipleUltrasound, Vibration, PressureHeat, Pressure
Plastic ThicknessUltrasonic welding can be used for thinner plastic parts than heat welding.
Size of workpieceHas size limitationAvailable for big large workpieces

Ultrasonic welding and heat staking have their own advantages and disadvantages. If you want to weld small or thinner plastic parts, you can choose ultrasonic welding equipment; if you want to weld large plastic parts or require higher welding strength, heat staking can be a good choice. It depends on the specific needs of your application.

If you need help and detailed suggestions, you can contact us directly. We have more than 15 years of experience in the welding field, always pursue perfect welding quality, and can provide you with one-stop welding technology solutions.

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