Videos & Resources / Why Thermal Assembly

Why choose thermal assembly to assemble your parts?

Thermal assembly is used to join two or more parts when at least one component is made of plastic. Thermal assembly (aka heat staking) offers several benefits for high-volume applications:

  • Thermal machines cost less
  • Thermal tooling usually costs less and lasts longer
  • Thermal assembly is very quiet compared to ultrasonic assembly (no mechanical vibration)
  • Thermal welds are 20% stronger
  • Inserting into filled material can be accomplished with less damage to the inserts with a thermal unit
  • Multiple stakes and inserts at different levels can be accomplished simultaneously with a thermal unit
  • Different sized inserts can be driven simultaneously with a thermal unit
  • Larger inserts or more inserts can be driven with one cycle of a thermal press than with an ultrasonic press
  • Thermal units work well on glass and mineral-filled resins
  • There is less damage or marking on the face of a molded part with a thermal unit
  • There is less mechanical force and therefore less stress on the part with a thermal unit
  • The thermal staking process is less likely to split the boss or damage other components
  • Thermal machines have very low maintenance costs
  • Reported to have 10% to 20% stronger holding retention for stakes and inserts
  • There are much fewer material limitations with the thermal assembly process

Toman Thermosonics is a full-service manufacturer of thermal assembly machines, accessories and supplies.

Contact us to share your thermoplastic assembly needs or shop our heat staking equipment.