Heat staking has many useful applications, whether that is in a clean-sheet design or revamping a current product. It is one of a handful of attachment methods to keep components together. The question always becomes which is best and why. In an effort to shed some light on heat staking, we’ve listed the top 5 reasons you need to look at heat staking on your next project:
Heat staking has five main variants that offer permanent attachment by melting the base plastic material into a shape that will hold a secondary component. A standard flared stake offers a simple mushroom with a dimple in the center. A spherical stake offers a rounded button-head shape. A hollow stake starts with a hollow boss of plastic that appears to be a cylindrical shape. The exterior walls of the cylinder are melted and folded over the edge of the secondary component to form the mechanical attachment without leaving a sink mark on the opposite side. A knurled stake should be used where appearance is not a critical design feature. The knurled stake is best used in high volume production as alignment isn’t critical for the function of the attachment. The last is a flush stake which is used in applications that require a flush surface after the plastic is melted and operation is complete. The flush stake necessitates that the retained secondary component has sufficient thickness for a chamfer or counter-bore connection point. The melted plastic resides inside the counter-bore and fills it with plastic to make the final mechanical connection. Which would be best for your product? That’s a great question we can help answer.
Heat staking can increase strength and quality, yet still be a low cost production option. It offers strength comparable to other operations involving secondary fasteners, and it doesn’t contaminate the finished product. Heat staking has proven to offer exceptional reliability, extreme durability, and corrosion resistance in harsh environments. Another benefit is that you don’t need to worry about eventual corrosion in the field due to dissimilar materials being used.
Using heat staking as an attachment method does not require any additional material such as an adhesive or a solvent to make the permanent bond. The only addition is the heat applied to melt the plastic and a tool to shape the plastic to form the mechanical connection. Skip the mechanical fasteners like screws or bolts, and the equipment to ensure a proper torque every time. Heat staking can reduce the assembly line set-up time, minimize process costs, and contribute to a clean work area.
In manufacturing, wasted time is wasted money. Taking one second or more out of every assembly operation can add up to minutes every hour that you’re making more products with increased efficiency. The heat staking operation can be completed in seconds, and it can be automated to reduce cycle time. That means your product can reduce manufacturing cost, which can directly lead to more profit.
Heat staking equipment is easy to maintain without an extensive maintenance program. Assembly personnel can use a simple Total Production Maintenance (TPM) process on a schedule to keep the process efficient and optimized. Imagine using a check sheet that all personnel can quickly verify the heat staking equipment and then run a full day of production without downtime.
At SEA-LECT Plastics we use many fastening methods for assembly, including heat staking. Our customer and in-house designed and assembled products range from military grade assemblies to the outdoor industry. Our experts can advise you on what may be the best option for your new product idea or how to change your current product to reduce cost, increase productivity, and also increase quality.
When you’re ready to work with our elite team on your next design concept, call (425) 339-0288 or email us at mattp@sealectplastics.mystagingwebsite.com
Matthias Poischbeg was born and raised in Hamburg, Germany. Matt moved to Everett, Wash., after finishing his bachelor’s degree in business in 1995 to work for Sea-Dog Corporation, a manufacturer, and distributor of marine and rigging hardware established in 1923.
In 1999, Matt took over the reins at Sea-Lect Plastics Corporation, a sister company of Sea-Dog and a manufacturer of plastic injection molded products with an in-house tool & die shop. Matthias Poischbeg is also a contributor to Grit Daily.
Plastic injection moulding is by far the most popular method for producing mass manufactured plastic products – though if you’re new to the design and manufacturing game, here’s a quick recap. An injection moulding machine has a few main elements; a material feeder, called a ‘hopper,’ where plastic granules are poured; a heated barrel that melts the granules down; a rotating and reciprocating screw that mixes the molten plastic and creates the pressure needed for injection; and finally a steel injection mould cavity tool which is made to take on the shape of your final product.
When it comes to manufacturing, it is one of the more desirable methods due to its simplicity and ease of process. If you’re well acquainted with the process, you will have seen the results and shouldn’t have any doubts about whether or not plastic injection moulding is the right method for your product design. But, just in case you do, here are 5 amazing benefits of plastic injection moulding that will surely convert you.
One of the most appealing benefits of plastic injection moulding is that it’s economical. Because most of the process is automated, manufacturing costs and overheads are significantly reduced. Don’t get it wrong, though, that doesn’t mean it cuts corners – automation allows for more precise and accurate plastic injection moulds, if anything. Computer aided design (CAD) and computer aided manufacturing (CAM) are the features of this process that drive accuracy.
For a start – it’s fast. How fast you, say? Plastic Injection Moulding generally only takes around 15 to 30 seconds between cycle times (although this can depend on the complexity of the part). Thousands of parts can be manufactured from a single mould, and this high production output is yet another feature of the process’s cost effectiveness.
Plastic injection moulding offers the choice to use fillers, which reduces the density of the plastic but also adds greater strength to the part after it has been moulded. This is an option that other moulding processes do not offer, which makes it an ideal process for industries or products where parts need to be durable and strong.
More and more, product developers (and the rest of us) are becoming aware of factors in product design that both benefit the environment and minimize waste. Plastic injection moulding is sustainable for both the user and the planet because it only uses as much plastic as necessary to create the part. Not only that, but if there is any excess plastic, this can easily be ground up and recycled after use.
Multiple plastics? No worries! Co-injection moulding can me used for multiple plastics, which takes away the stress of having to be specific. Co-injection moulding machines are designed especially to bring together different types of plastics to produce your desired end product with accuracy, so you won’t be sacrificing any of the benefits of injecting with one particular type of plastic.
Plastic injection moulding is one of the most popular processes for producing plastic parts, and with good reason. If you would like to have a chat about injection moulding for your part, book a free consultation with us today!