Industries We Serve - Toman Thermosonics

Below is an overview of some of the industries that most utilize our thermal and pneumatic presses in their manufacturing processes for heat staking, sealing, swagging, inserting, de-gating, bending, forming, punching, and branding their parts.

Our thermal and pneumatic press assembly machines integrate heat and pressure systems combined with sensors, controllers, computers, and actuators for processing parts. One such application termed “Heat Staking” reforms a plastic stud or boss, pressing it over a mating component to mechanically lock the parts together. This heat staking method is ideal when a metal insert or fastener isn’t desired. Parts manufactured for products in the industries shown below often require tight tolerances. Thermal presses used for heat staking provide repeatable temperature, pressure, and dwell-time control, ensuring consistent results across high-volume production. Many assemblies use multi-point heat staking setups—allowing multiple stakes to be formed simultaneously. Custom tooling ensures perfect alignment with complex geometries.

Automotive Industry

Common Applications: Interior Assemblies — Instrument panels and dashboards, HVAC vents and control modules, Door panels, trim components, and center consoles, Electrical and Electronic Components — Control units and ECU housings, Lighting assemblies, Sensor and switch enclosures, Under-the-Hood Applications — Fluid reservoirs and brackets, Wire harness retainers and connectors.

Key Advantages: Lightweight assembly — eliminates metal fasteners and reduces overall vehicle weight. Cost efficiency — no consumables like screws or adhesives. Durability — vibration-resistant joints that withstand temperature and mechanical stress. Clean and quiet process — no fumes, glues, or noise typical of ultrasonic welding. Design flexibility — works with complex shapes and sensitive components.

Medical Device Industry

Common Applications: Diagnostic Devices – housings for analyzers, testing cartridges, and lab instrumentation. Patient Monitoring Equipment – enclosures for monitors, sensors, and connectors. Fluid Management. Systems – pump housings, tubing manifolds, and valve assemblies. Single-Use Devices – disposable instruments, cartridges, and filter assemblies. Electronic Medical Components – control modules, power units, and battery compartments

Key Advantages: Clean and Contaminant-Free – no adhesives, solvents, or ultrasonic vibration. Repeatable Quality – precision control ensures compliance with regulatory standards. Hermetic Seals – excellent for moisture- or contamination-sensitive devices. Compact and Lightweight Assemblies – eliminates hardware, reducing material costs. Customizable Tooling – supports complex geometries and multi-point staking for high-throughput production.

Electrical Appliances Industry

Common Applications: EV Batteries – sealing housings for individual cells. Electrical Connectors & Busbars – insulating holders and protective housings. HVAC and Climate Control Systems – thermostat housings, air filter frames, and control modules. Lighting and Power Devices – LED housings, switches, and electrical connectors

Key Advantages: Strong and Repeatable Joints – ensures reliability under thermal and mechanical stress. Clean Assembly – no adhesives or vibration that could damage sensitive electronic parts. Aesthetic Finish – smooth, mark-free results ideal for visible product surfaces. Lightweight and Cost-Effective – eliminates hardware and reduces material costs. Scalable for Automation – compatible with multi-point tooling and robotic systems.

Military and Defense Industry

Common Applications: Communications Equipment – ruggedized radios, satellite terminals, and control panels. Weapon Systems – housings, mounts, and sensor enclosures. Vehicle Components – dashboards, electronic modules, and interior panels for military vehicles. Unmanned Systems & Drones – battery enclosures, sensor mounts, and control housings. Field Electronics & Power Systems – portable generators, power converters, and connectors.

Key Advantages: Durable, Mission-Ready Joints – withstand vibration, shock, temperature extremes, and moisture. Clean and Controlled Process – no adhesives, solvents, or ultrasonic vibration that could compromise sensitive electronics. Repeatable Quality – precise control ensures compliance with military specifications and standards. Lightweight Assemblies – reduces weight without sacrificing strength. Adaptable Tooling – custom and multi-point staking solutions for complex assemblies.

Consumer Products Industry

Common Applications: Home Appliances – coffee makers, blenders, vacuum cleaners, and air purifiers. Personal Care Products – electric toothbrushes, hair dryers, and grooming tools. Electronics & Gadgets – remote controls, chargers, wearable devices, and gaming accessories. Toys & Recreational Products – electronic toys, fitness devices, and hobby equipment. Kitchenware & Storage – food containers, dispensers, and organizational products.

Key Advantages: Durable Joints – reliable assemblies that withstand daily use. Clean & Efficient Process – no adhesives or screws, reducing assembly time and contamination risk. Aesthetic Finish – smooth, mark-free results suitable for visible product surfaces. Cost-Effective Production – eliminates fasteners and reduces material costs. Scalable & Flexible – multi-point and custom tooling for high-volume or intricate designs.