Techniques for Successful Manufacturing Using Plastic Welding

April 14, 2017 2:21 pm Published by

Attaching plastic components often feels like an exercise in futility. There are few glue products that bind plastic, and even if you find one that works, it is unlikely to be permanent. Plastic welding in UT is the best alternative to glue, whether you run a manufacturing outfit or perform crafts at home. Here are nine welding techniques that work great for plastic:

  • Hot gas welding: The primary tool for this technique is a welding gun using electric or gas-heated chambers. Operators may add nitrogen cartridges, or the guns take dry air from the environment. The heated gas focuses on the joint to be welded and binds to a part made from the same materials.
  • Spin welding: Used for attaching components at a cross-section, spin welding creates heat by rotating them. This happens due to friction. The technique is performed manually with a drill press, with constant checking to control heat levels. At professional shops, this process is automated to coordinate feeding, timing and pressure before ejecting the combined parts.
  • Friction welding: Rather than use gas or dry air to heat the plastic for welding, this method uses rapid angular oscillations. This spin welding process is best used for parts that are not symmetrical to the rotation. Equipment doing the spinning is programmed to stop when the welding process is finished.
  • Laser welding: When you need precision, laser welding is the best option to consider. The laser beam produces heat and pressure along a joining line to create a permanent weld. This is used when attaching small components together or to create components under detailed specifications.
  • Induction welding: Starting with a heated metal insert, an operator holds the components together using pressure. A high-frequency generator raises the temperature until the plastic softens and welds together. Rapid cooling secures the joint.
  • Solvent welding: Hard plastics often require the use of a solvent. This can be a touchy process because too much solvent can destroy the component. Applying just enough of the solvent to soften plastic, the plastic pieces are pressed together while the solvent evaporates or is absorbed. This creates a cement-type bond that remains secure.
  • Extruded-bead sealing: The welder starts by creating a heated bead made of the same material as the components. It is placed between the two parts as they are pressed together. The flattened bead acts as a cohesive that binds the components together.
  • High frequency welding: A high-frequency generator heats joints with electrodes, which essentially creates a bead, much like with the extruded-bead sealing process. The heated surfaces are pressed together to connect the components.
  • Hot tool welding: This method is frequently used when two large surfaces need to be bound together. The other methods do not cover enough area to assure even cohesion and security between the objects. A welder first heats the surface of one component against a hot plate to melt the top layers. Quickly, that component is pressed against the other part to seal them.

D&D Plastics offers many options for fabrication, including plastic welding in UT. Call us today to see what we can do for you.

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