November 3, 2026 · admin
Ultrasonic welding and heat staking are both used to assemble plastic components, and sometimes to secure other parts such as metal inserts. They work differently, so the better choice depends on the part, the cycle time and the finished appearance needed.
How Each Process Works
- Ultrasonic welding uses high-frequency vibration to generate heat at the joint. See the working principle.
- Heat staking uses a heated tool to melt and reform a plastic stud or boss so it holds another part in place.
Comparison
| Factor | Ultrasonic welding | Heat staking |
|---|---|---|
| Heat source | Vibration at the joint | Heated tool applied to the part |
| Cycle time | Usually very short | Depends on heating and cooling of the tool |
| Typical use | Joining and sealing plastic parts, spot welding, inserting | Securing parts with a reformed plastic stud |
| Tooling | Horn tuned to the part | Heated tip shaped to the stud |
| Consumables | None | None |
| Part design | Joint must suit ultrasonic welding | Needs studs or bosses to form |
When to Choose Ultrasonic Welding
- You need to join or seal two plastic parts.
- Short cycle times matter.
- The plastic welds well ultrasonically. See suitable materials.
When Heat Staking May Suit
- The design already uses plastic studs or bosses to retain a component.
- The material or geometry is unsuitable for transmitting ultrasonic vibration.
Ultrasonic equipment can also stake, spot weld and insert components. To discuss your assembly, see our ultrasonic spot welding machines or contact JSB Ultrasonic.
