Thermal Processing

Custom applications powered by professional engineers


Equipped with optional Allen Bradley PLC, part shuttle, stand and enclosure with Blanchard ground top, light curtain and quick change upper and lower tooling. This system was built to assemble automotive tail light assemblies.
The tooling was designed to stake an LED Array and Circuit Board into the assembly in the left side of the tooling. The assembly is then placed in the right-hand side of the tooling where a plastic Clinch Cover is staked in place. The tooling was designed to accept precision alignment stanchions. This allows the operator to change the tooling as a die set to reduce set-up time.

Heat Staking

Heat staking allows plastic or metal to be joined to a plastic boss by swaging material in the form of a "rivet" head. (Stringing of material can be eliminated by the tip cooling option)

Key Benefits

1. Simplification of Machinery
2. Reduced Cost of Machinery
3. Multiple Fastening Points
4. Higher density of welds compared to hot-air-cold-form or ultrasonic welding.
5. Many different size or shaped heads can be formed

Hot Air/ Cold Stake

Utilized to join plastic or plastic to metal, forming a permanent, tight assembly. Virtually an unlimited number of stakes can be simultaneously staked, formed, folded, or crimped into a predetermined geometry. This process has a unique benefit to typical heat staking due to the heating elements being contactless, thus eliminating any stringing on plastics prone to this characteristic. Cycle times are quick and the process is extremely consistent. The result is a high production speed, with consistent results and low production cost.

TurnKey Technologies HACS system is a process that reforms a thermoplastic stud into a shape that joins plastic to plastic or, plastic to metal, producing a permanent , tight assembly. Below is an illustration of the process. 

Hot Plate Welding

Hot Plate Welding allows plastic components to be welded together to produce a monolithic plastic assembly.
The animation to the left shows a heated element in purple which traverses between the parts to be welded (blue). The parts are shuttled into the heated platen and held there until a predetermined amount of material has been melted. The 2 parts are then separated slightly from the heated platen, and brought together under pressure. The parts are held together until the plastic has re-solidified.  

Key Benefits

1. High Strength Weld
2. Large Surface Area Welds
3. Hermetically Seals
4. Highly Contoured Weld Surface Capability
5. Contact or Non-Contact Heater Platens
6. Optional Easy Change Tooling
7. Optional Heater Burnout Indicators
8. Optional Vertical or Horizontal Motion
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