Technology: Thermal Plastic Staking

Thermal staking of thermoplastic parts is an effective method of joining large parts or assemblies comprised of dissimilar materials. Thermal staking produces exceptionally high quality formed stud or boss heads.

Thermal plastic staking is the process of reforming a protruding plastic stud or hollow boss in order to lock, or sandwhich, another component of the assembly in place. A heated tool tip with a custom cavity contacts the stud or boss to heat, flow, and form the head. Successful thermal staking applications require the correct calibration between heat and applied pressure.

The advantages of thermal staking include:

Less capital equipment cost compared to ultrasonic staking, especially as the number of studs or bosses formed per cycle increases.
Able to form studs or bosses on several planes simultaneously.
Produces highly aesthetic formed heads.
Equipment technology is easily scalabe (Arbor, Pneumatic, and Servo actuated systems are available).

Stud and boss designs include standard dome, flared, hollow, knurl, and flush. Each design provides different benefits regarding cycle time, strength, and clearance concerns. Contact AMS to discuss your application or receive design guidance.

Click the "A" Application button to view an exampel of a thermal staking applications.