PulseStaker Process


PULSESTAKING is a process for plastic reforming. This is commonly known as heat staking or swaging. The patented PULSESTAKER has individual tip heating control that rapidly achieves its operating temperatures (typically 1 second depending on the tip size) by passing a high current through the forming tip (see figure below). The current may be controlled to allow the tip to heat and cool as often as required to form the stake point (typically once or twice is sufficient).

By utilising a PLC, adjustments of current and air blast timing (to a fraction of a second) are made individually on each tip enabling total control of the staking process. The process is a single stage process with the heating and forming being carried out in the one operation. Because of the nature of the process the possibility of processing damage to ‘Class A’ surfaces is eliminated. Staking can be performed individually or with a large number of stakes being carried out simultaneously. Staking cycle times can range from 2 seconds to 15 seconds, limited by the volume of material to be reformed.


1. Flat Tip Welding: This application is used in the assembly of battery terminals and metal plate fixing. 


2. Polymer to Polymer and other Materials:The most common application is where the material   with the boss is thermo


 3. Polymer to Polymer: This is similar to the previous application except that both materials are the same and the stake point is deeper. This creates an ideal seal. The application is used in the assembly of cooling pot lids and fishing reels.

  4. Bonding: A fibrous material without a hole in the material - the application is used in the assembly of sound damping material to automotive pillars, doors and panels.
   5. Rim Swaging: To lock parts in position - this application is used in the assembly of cameralenses and retaining bearings.
   6. Sealing Holes: This application is used in the assembly of relay cases, blow moulding gates and security sealing.
   7. Embedding Parts: Including bolts or pins, sealing holes or access to screws - this application is used in the assembly of cellular phones and automotive components.
   8. Polymer to Mesh: This application is used to bond a mesh without making a hole in the mesh. The application is used inthe assembly of automotive louvered covers or filter fixing.
   9. Welding: This application is used to fix two plastic parts together.





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