Heat staking system for retrofitting into a customer rack.

If required, we can retrofit the heat staking components into a ready-made customer rack. The required components such as the multiple heat staking head, control cabinet and operator control panel are fitted into the housing to meet customer requirements, integrated into the rack and then tested.

In this example, a circuit board with a 6x heat staking heads is fixed in the plastic housing.


Temporarily heated system, where active cooling of the product takes place after the heating phase.

Custom-built systems and special machines are designed, manufactured, tested and commissioned for operation in our factory. We carry out all the manufacturing stages required for the heat staking process.

We can meet customer functional specifications from simple systems, which are purely thermally monitored, to completely process-monitored expansion sections with component raised- and lowered-distance measurement, permanent force measurement and data communication.

The relevant heat staking tools are matched to the product and the control circuit of the system is designed for the connection of single dies to the use of complex, multiple heat staking heads (e.g. for use in staking of 10 or more simultaneous processes. The shaping dies are manufactured in-house to meet customer specifications. The heat staking heads can be very rapidly changed over.

Our innovative coating technologies ensure the maximum possible operating life of the heat staking die even with extremely compact plastics and provide maximum resistance to the abrasive wear and erosion to which the forming surfaces in contact with the product are exposed. Coatings with a micro hardness (HV 0.05) up to 3,300 are used.

System control allows freely programmable heating and cooling phases, comprehensive monitoring functions (warning- and malfunction messages for all possible parameters), workpiece or maintenance counters, storage of manufacturing parameters for 10 or more products, possibility of displaying all identified process parameters etc. All changes to process-relevant parameters are password protected. Serious fault reports, (such as the breaching of malfunction values or repeated alarms) can only be overridden by means of an additional key switch.

A heat staking system for integration in a customer in-line system (E.G. the Bosch TS) with workpiece carriers. In this example, the heat staking process was split into two work stations with a total of 6 positions. At each station, 3 plastic pins were formed into dome shapes. Multiple heat staking heads can be used.

The control of the belt section of the in-line system can be taken over by the heat staking system or by the customer’s control system. The circulating workpiece holders are indexed into the working stations or raised. The indexing units are specifically designed for the fairly high forces encountered in the heat staking process. The integration of the heat staking control into the customer system takes place by means of standard interfaces (digital input/output, Profibus or TCP/IP network). The functionality of the heat staking system can therefore be monitored and controlled or process data can be transferred (Traceability)

Temporarily heated system, where active cooling of the product takes place after the heating phase.

Custom-built systems and special machines are designed, manufactured, tested and commissioned for operation in our factory. We carry out all the manufacturing stages required for the heat staking process.

We can meet customer functional specifications from simple systems, which are purely thermally monitored, to completely process-monitored expansion sections with component raised- and lowered-distance measurement, permanent force measurement and data communication.

The relevant heat staking tools are matched to the product and the control circuit of the system is designed for the connection of single dies to the use of complex, multiple heat staking heads (e.g. for use in staking of 10 or more simultaneous processes. The shaping dies are manufactured in-house to meet customer specifications. The heat staking heads can be very rapidly changed over.

Our innovative coating technologies ensure the maximum possible operating life of the heat staking die even with extremely compact plastics and provide maximum resistance to the abrasive wear and erosion to which the forming surfaces in contact with the product are exposed. Coatings with a micro hardness (HV 0.05) up to 3,300 are used.

System control allows freely programmable heating and cooling phases, comprehensive monitoring functions (warning- and malfunction messages for all possible parameters), workpiece or maintenance counters, storage of manufacturing parameters for 10 or more products, possibility of displaying all identified process parameters etc. All changes to process-relevant parameters are password protected. Serious fault reports, (such as the breaching of malfunction values or repeated alarms) can only be overridden by means of an additional key switch.

Heat staking system for use with a hand held thermode.

A temporarily heated system, where active cooling of the product takes place after the heating phase.

This system is intended for applications which allow manual feed of the heat staking die.

The operator feeds the heat staking die, which is fixed to a handle, to the product to be heat-sealed and he then starts the heat staking process by means of a separate starter switch or a foot switch.

The heating phase, programmed into the control system, is started and the product is formed under the manual forcing action of the operator.

Typically, the heating phase runs to 2-3 seconds.

After the heating phase, the die and the formed product are actively cooled at the programmed temperature. The die can finally be removed from the product.

The total heating process can be programmed as required in the control system and is monitored in correspondingly adjustable limits.

Warning – and malfunction messages relating to over- and under-temperatures are reported to the operating control panel.

Furthermore, the heating process is also monitored by an additional temperature sensor fitted to the die.

Interchange or replacement dies can be replaced very quickly via a plug connection and can be calibrated into the system in less than a minute by means of the automatic calibration function.

The forming die is tailor-made or adapted by us. And there are no limits to the shape.

Our innovative coating technologies ensure the maximum possible operating life of the heat staking die even with extremely compact plastics and provide maximum resistance to the abrasive wear and erosion to which the forming surfaces in contact with the product are exposed. Coatings with a micro hardness (HV 0.05) up to 3,300 are used.

Please be aware that not all applications are suitable for manually applied force during the staking process. Please contact us and we will gladly advise you in the selection of the most suitable system.

Heat staking system with a permanently heated tool/heat staking head.
Specially developed design for plastic forming processes. can be used in a permanently heated forming tool. Typical applications are heat staking of Teflon membranes in or on a thermoplastic material.. There is no need for cooling after the heat staking phase.

Temperature range according to application is for example 50-500°C, the process time is freely adjustable.

The tailor-made tool, after a warm-up phase between 0.5 to 3 minutes depending on the application, is held at a constant temperature, monitored by the control system within adjustable limits. A path measurement is not possible within the framework of permanently heated systems. Optionally, power measurement can be optionally integrated.

The forming tools can be easily removed after cooling and the system can then be used for different applications.

Including: two hand control, Emergency shut down and CE identification/marking. Components can be fed into the system optionally via a slide table or a turntable.

Typical hot caulking head for integration in customers’ production systems. Three heat sealers are simultaneously fed to the product but can each have different operating parameters.

A system for forming thermoplastic components under the action of heat and force e.g for fixing circuit boards in plastic bases or for plastic-plastic deformation.

Thermoplastic materials such as PA, PP, PBT, POM, PC and PE (also with glass fibre content) are caulked.

High precision temperature control using the pulse heat process. Connectivity for up to 3 single- or multiple heat sealers.

Pneumatic feed of the sealer onto the product. The heat sealers are double temperature monitored and the smallest temperature irregularity is automatically identified by the system. The hot caulking system can be fitted with integral force and path measurement. Sealers are not subject to contamination and can be coated to withstand mechanical wear, especially for applications using glass-fibre-filled plastics.

Typical heat staking head for integration in customers’ production systems.

Three heat sealers are simultaneously fed to the product but can each have different operating parameters.

A system for forming thermoplastic components under the action of heat and force e.g for fixing circuit boards in plastic bases or for plastic-plastic deformation.

Thermoplastic materials such as PA, PP, PBT, POM, PC and PE (also with glass fibre content) are caulked.

High precision temperature control using the pulse heat process. Connectivity for up to 3 single- or multiple heat sealers.

Pneumatic feed of the sealer onto the product.

The heat sealers are double temperature monitored and the smallest temperature irregularity is automatically identified by the system.

The hot caulking system can be fitted with integral force and path measurement.

Sealers are not subject to contamination and can be coated to withstand mechanical wear, especially for applications using glass-fibre-filled plastics.