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Heat Staking Procedures and Processes: Procedures, Process Parameters, and Guidelines For Plastics Assembling

The heat staking process precisely controls heat and force to join plastic parts through direct contact heating of metal probes. It offers benefits like repeatability, cleanliness, and cost effectiveness compared to other plastic joining methods. Key factors for a successful heat stake include proper post diameter, height, geometry, and material selection. Different post shapes like flat, dome, cross, and rosette can be made depending on the application's needs. Heat staking provides an efficient way to assemble a wide variety of plastic parts for applications in industries like electronics and automotive manufacturing.

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212 views4 pages

Heat Staking Procedures and Processes: Procedures, Process Parameters, and Guidelines For Plastics Assembling

The heat staking process precisely controls heat and force to join plastic parts through direct contact heating of metal probes. It offers benefits like repeatability, cleanliness, and cost effectiveness compared to other plastic joining methods. Key factors for a successful heat stake include proper post diameter, height, geometry, and material selection. Different post shapes like flat, dome, cross, and rosette can be made depending on the application's needs. Heat staking provides an efficient way to assemble a wide variety of plastic parts for applications in industries like electronics and automotive manufacturing.

Uploaded by

awdhut kulkarni
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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Heat Staking Procedures and

Processes
Procedures, Process Parameters, and Guidelines for Plastics
Assembling
The heat stake process is used in many high technology fields and
consumer products manufacturing and offers many benefits.
Direct Contact Press Methods Using Precisely Heated Probes and
Pressure
Thermal Press International, has developed a procedure that precisely
controls heat and force in providing a high quality, clean, odorless, and
safe upset heat stake procedure of modern thermoplastics. The heat stake
process gives you repeatable performance without the high cost & noise
of other types of processes.
Processes & Procedures for Staking
The direct contact method of staking applies force to heated metal probes,
which contact posts then compress & form a stud head, For joining
assemblies, metal to plastics, or joining two pieces of any another
material. Excellent heatstaked results are possible when the post &
material selection are initially configured for a heatstaking application.
Precise heat & pressure can reform posts from a wide variety of
thermoplastic materials. Some of the most common examples are abs,
polypropylene, polycarbonate, abs polycarbonate blends,
Polypropylene/polycarbonate blends & many other engineering materials
(even with as much as 30% filler).
Design Guidelines
Very simple design guidelines are required for success. There are a
number of factors that are essential in obtaining good heat stake results:
post diameter, height, & geometry. Working height, (above the mating
surface) should be approximately one & a half – two times the dia. This
will result in a heat stake stud head dia. of approximately 1.5 – 3.0 times
the post diameter. The selected material and its moldable thickness of the
walls will determine typical diameters. For example, diameters can range
from 0.04 – 0.09 inches.
Post Types – Flat Profile, Dome, Cross-Shaped, Rosette
Heat Staking posts & stud head geometry can vary as the application
dictates. For through-hole fastening post: maintaining a flat-tipped probe
tool for making a stud head into a flat profile is the easiest. Dome-shaped
stud heads are aesthetically attractive plus provide a tight heat staked
assembly (typically, tighter than the flat-tipped profile configuration), but
require a dome-shaped relief be machined into the tip of the probe.
Cross-shaped post or hollow boss staking can be used where high
retention assembly is required, but the design is limited because of the
existing part constraints. The hollow & cross post designs allow the
creation of large posts or thick rib sections of uniform thick wall thickness,
while minimizing or eliminating sink marks on the A-side rib surfaces.
Rosette-shaped heat stake probes will flair out a hollow boss leaving the
hole available for other operations (i.e. attaching additional components
using self-tapping type hardware). A rosette-shaped flair stud head is
aesthetically pleasing, plus has high pull strength characteristics
(compared with other configurations previously mentioned), but requires
more precision in the engineering and manufacturing of the probe.
Side Swaging
Side swaging is used for post requiring the retention of glass lenses or
other components. Side swaging can be successfully accomplished using
angled contoured probes, used in forming the post or side – walls,
capturing the component by its edge.
Clamping devices can be designed into the staking procedures ensuring
proper contact & tightness of the assembled units. When joint clamping
devices are used they can virtually eliminate joint gaps caused by warped
parts, poorly fitting parts, & operator errors.
Efficient Dis-assembly and Reworking
Reworking a heat staked assembly is performed efficiently & consistently
using heat staking. Dis-assembly is accomplished by piercing the stud
head with a hot pointed-tip probe, re-flowing the stud head material:
allowing a quick, clean removal of the stud head. A second set of posts for
an additional heat staking operation or an alternate fastening system can
be used in reassembling previously reworked parts.
Conclusion
Plastic Heat Staking is found in most industries and high technology fields
that manufacture thermoplastic assemblies. Examples include: consumer
electronics, automotive, telecommunications, medical device
manufacturers, computer manufactures, PCMCIA cards, Memory
Modules, Flash Cards, electronic badges, etc.
Using the direct contact press, heat stake method for assemblies is
repeatable, economical and safe. The number of posts heat staked at one
time is only limited by the configuration design of the parts being
assembled.
Heat staking and sealing parts of all shapes and sizes provides an
excellent means of plastic assembly. The benefits of being extremely
quite, plus the versatility of doing a wide range of high tech post; from
threaded inserts and other metal components, to micro miniature
equipment assembly by providing cost effective means of adding or
changing tooling make the process an excellent return on investment. In
addition: the minimal wear characteristics of the tooling, low maintenance
costs, high reliability of the equipment, and the added benefits of being
safe for the environment provide for a long, trouble free, and clean
operation.
We can help you today with your engineering, prototype development,
and manufacturing needs. See how Thermal Press International can save
you dollars on the bottom line while solving your most demanding
assembly issues using our direct contact heat staking machines.
Contact Us at Thermal Press for more information.

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