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Two-Phase Thermoforming

Join two different kinds of materials

The Two-Phase Thermoforming process connects two different kinds of materials given that one of these materials is thermoplastic. There are no problems in riveting/staking parts with critical surfaces (painting, foil, graining…)

Particle free welding process

In this process, the plastic pin is plasticized and gets softer with a contactless heating source which eliminates friction and particles.

No pollution on the heating element

No material adhesions on the tools even for materials with low viscosity because of the contactless plasticization and “cold” forming punch.

Lower mechanical stress on the components

Since force is applied in the 2nd phase when the plastic pin is already plasticized by a non-contact heating element, it reduces mechanical stress.

Reduce cycle time with Rotary Table

Heating, turning, and riveting can be separated in three steps using a rotary/turntable to reduce cycle time. It also has the ability to simultaneously riveting (more than 30 points are proven).

Two-Phase Thermoforming
Two-Phase Thermoforming
Two-Phase Thermoforming
Two-Phase Thermoforming

Overview

The Two-Phase Thermoforming can be used for all thermoplastic materials; therefore, plastic-plastic and plastic-metal can be assembled without any problems.

It has significant advantages over traditional thermal staking, ultrasonic staking, and IR processes such as the infra-stake. With traditional processes, the proximity of the forming tips is limited by either the diameter of the transducer or the diameter of the heating device. The Thermoforming process is not limited by these constraints since the gas delivery nozzles can be placed as close as 3-4mm center-to-center.

This procedure is well suited to connect components through a backlash-free and positive-locking rivet connection. The rivet connection is formed by the thermal shaping of a rivet peg to generate high-strength joints.

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Key Features

  • Connect different kinds of materials given that one of the material is thermoplastic
  • No problems in riveting/staking on parts with critical surfaces (painting, foil, graining…)
  • Particulate free riveting process
  • Radiant heating, no contact to the part
  • No pollution on the heating element
  • Free of clearance after riveting
  • Riveting or staking of nearly all kinds thermoplastic materials
  • Less mechanical stress on the components (eg. PCB) as ultrasonic riveting
  • No material adhesions on the tools also for materials with low viscosity, contactless plasticization and "cold" forming punch
  • Possibility of simultaneously riveting (more than 30 points are proven)

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