Metal to Plastic Insertion with Induction

Ambrell has over 10,000 systems installed in over 50 countries and many of them are metal to plastic insertion applications.

metal-to-plastic-insertion with induction

Improve your metal to plastic insertion process without flame! Staking with induction heating focuses energy in your part only. You don't need a torch or a costly batch or furnace process. Stake your materials in a repeatable, precise flameless process.

We offer exceptional customer service before and after the sale. Your metal to plastic insertion application will be analyzed and tested in the nearest Ambrell Applications Lab. There is no charge, and you will receive a system recommendation designed to deliver the best possible solution for your brazing requirements. Ambrell delivers the expertise, innovation and system quality to give your company a competitive edge.

Heat Staking: Inserting Metal Into Plastic

Heat Staking: Inserting Metal Into Plastic

One of the most common uses for induction heating is the heat staking of threaded metal inserts into plastic. Most thermo-plastics are too soft to sufficiently hold a thread, so brass or steel threaded inserts are added.

Click to read one of our metal to plastic insertion Application Notes (after a brief registration). Learn more about:

Heat Staking: Industrial Heating Magazine

Heat Staking: Industrial Heating Magazine

by Girish Dahake, PhD., Ambrell an Ameritherm Company

Injection-molded plastic parts are used increasingly in industry, particularly automotive because of their strength and reduced weight when compared to metal. Read more.

Also PT

When a structural component is produced from a thermoplastic material, it is possible to heat a threaded metal insert to a temperature above the plastic reflow point and press it into the plastic part. There are many types of metal inserts, specially designed for retention strength, produced for this purpose. With the increasing need for lighter, stronger structural components, metal inserts are now frequently used when strong threaded connections are required. Metal to plastic bonding is one of several plastic reflow appli-cations for induction heating. Other processes involving heating plastic to a liquidous state include metal reclaiming and thermoplastic composite manufacturing.

metal to plastic insertion image

The metal to plastic bonding process requires fast, accurate and repeatable heating to avoid such quality defects as flashing (molten plastic overflow) and burning. Modern induction heating systems quickly heat the inserts from the outside surface, limiting the heat energy to the outer edges where heat is needed to reflow the plastic. Longer heating cycles may result in the softening of the internal threads, especially at the low temperatures needed for heating brass inserts. Heating with induction is reliable, repeatable, non-contact and energy-efficient. Solid state systems, when used in conjunction with temperature sensing and control equipment, are capable of heating very small areas within precise production tolerances.

Typical RF power supplies for metal to plastic bonding range from 1 to 20kW, depending on the parts and application requirements.

utm_medium material docid title blurb
metal-plastic-insertion brass metaltoplastic_16 Heating four brass inserts prior to insertion into a plastic motor housing Using induction heating, the parts came to the required temperature in just 15 seconds in a highly repeatable heating method and a coil plate could offer protection against operator movement/errors
metal-plastic-insertion stainless steel metaltoplastic_15 Heating stainless steel inserts for an insertion application Induction offers dramatically faster heating when compared to ultrasonics; faster heating means there is the potential to dramatically increase production rates with a highly repeatable and easy-to integrate processes.
metal-plastic-insertion brass metaltoplastic_14 Heating brass inserts for metal-to-plastic insertion Innovation: Ambrell’s Applications Lab was able to solve a problem that a competitor couldn’t solve, which is a key benefit when purchasing induction solutions from Ambrell
metal-plastic-insertion   metaltoplastic_13 Bonding plastic handles onto metal brooms With a more reliable induction heating system, they will not have to worry about lost production due to power supply issues that come with an unreliable system
metal-plastic-insertion steel metaltoplastic_12 Metal-to-plastic insertion of threaded magnetic steel inserts Outdated equipment and poor responsiveness drove this customer to a new vendor who could help them with new or improved processes for new or enhanced solutions
metal-plastic-insertion   metaltoplastic_11 Bonding an Arthroscopic Device Induction is used to bond the device sheath to collet. Innovative coil design lifts production rate.
metal-plastic-insertion   metaltoplastic_10 Heat a steel shaft for metal-to-plastic insertion Induction heating provides hands-free heating that involves no operator skill for manufacturing, even distribution of heating and localized application of energy limits temperature drift
metal-plastic-insertion   metaltoplastic_9 Inserting brass bushing into plastic wire connector A three turn helical coil is used to heat the brass bushing. The brass bushing is heated for 2 seconds and then placed on the wire connector & pressed into position.
metal-plastic-insertion   metaltoplastic_8 Heating magnetic steel for insertion into polypropylene for pallet manufacturing Induction heating provides “greener” manufacturing of pallets using reusable, recyclable materials, hands-free heating that involves minimal operator skill for manufacturing and even distribution of heating
metal-plastic-insertion   metaltoplastic_7 Inserting threaded brass parts into plastic thermostat housing This application has three different coils for varying hole patterns. A three turn oblong coil is used to heat 2 brass inserts in close proximity.
metal-plastic-insertion   metaltoplastic_6 Inserting a piston stop with o-ring into an oil pump assembly Induction heating provides increased production speed, simpler tooling for customer, hands-free heating that involves no operator skill for manufacturing
metal-plastic-insertion   metaltoplastic_5 Bonding of electric motor shaft to nylon face fan Induction heating provides hands-free heating that involves no operator skill for manufacturing, only the metal shaft is heated so the motor is not affected, increased production due to rapid heating, decreased failure rate, originally used glue which ran into motor and caused failure and stronger bond
metal-plastic-insertion   metaltoplastic_4 Heating Four Inserts Simultaneously The brass inserts are to be heated prior to insertion into a plastic automotive sub assembly
metal-plastic-insertion   metaltoplastic_3 Brass Inserts Heating is to be accomplished within 5 seconds, and can be done in a helical coil since “pick and place” manufacturing is employed.
metal-plastic-insertion   metaltoplastic_2 Plastic Lawn Chairs To heat internally threaded steel inserts to a temperature above 650F for insertion into plastic lawn chair assemblies.
metal-plastic-insertion   metaltoplastic_1 Brassiere Underwire To heat the ends of 0.072" spring wire, spaced 1/2" apart, uniformly for the application of nylon powder on a 1" length of the end.