Assembly
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Heat Staking
Did you know?
Heat staking is a process that provides a mechanical lock
between two parts. Heat is applied to melt a plastic boss
or stud and once solidified, the re-formed plastic holds the
parts in place (see figure 3).
How does it work?
Staking can be accomplished using heat or ultrasonic energy
and pressure. They both use a tool that is contoured to provide
the final shapes as shown below. The pressure is applied until
the plastic reshapes and solidifies.
Things to consider:
- Resin – glass or mineral filled materials require hardened steel or carbide tips on the tool to increase tool life.
- Assembly time – staking needs to be slower to allow even melting. Cold pressing the boss can lead to internal stress and breaking.
- Cost of equipment and availability.
- Ultrasonic energy provides less heat in the tip of the tool. This will form a cleaner weld.
- The horn should provide a contour that will contain the melt and allow for tight assembly.
- There are a number of different staking profiles (see figure 4). The standard profile should have twice the diameter of the original boss or stud.
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