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ERW- Electromagnetic resistance welding

Indirect plastic heating

The insert distributes heat evenly, softening the plastic without risking thermal damage. 

No mechanical stress

Contactless heating means the insert isn’t physically stressed, increasing the strength and reliability of the bond. 

Clean Process

No particles are generated, making this method especially suitable for applications with strict cleanliness requirements. 

Precise Placement

A pressure control system and a physical stop ensure the insert is embedded at exactly the right depth. 

Fast Cooling

Immediate air cooling after embedding prevents the insert from moving and locks it firmly in place. 

Consistent Results

The process delivers repeatable, high-precision results, even in high-volume production. 

Material-Friendly

Both the insert and the plastic are protected from heat-related damage. 

 

ERW- Electromagnetic resistance welding
ERW- Electromagnetic resistance welding

Overview

ERW welding (Electromagnetic Resistance Welding) by Dukane is a precise and efficient method for securely embedding metal inserts into plastic parts. The process uses inductive heating to soften the surrounding plastic, creating a strong and durable bond between the insert and the plastic, without mechanical stress or particle contamination. 

How does EWS welding work? 

With EWS welding, the metal insert is heated using electromagnetic induction. This contactless method ensures the insert heats evenly and transfers that heat to the surrounding plastic. As a result, the plastic softens indirectly, avoiding overheating or material damage. 

Because the insert isn’t physically touched or pressed during heating, no mechanical stress is applied, making the process especially gentle and safe. Additionally, the method produces no particles, which makes it ideal for cleanroom or sensitive manufacturing environments. 

Applications of EWS Welding 

EWS welding is used in a wide range of industries, including: 

Automotive 

Medical technology 

Electronics 

Packaging 

It’s particularly well-suited for situations where metal inserts need to be embedded into plastic components with high accuracy, without damaging the materials, and where a clean, particle-free process is critical. 

Why choose EWS welding from Dukane? 

Dukane offers customized EWS welding solutions tailored to your specific production needs. Our advanced technology ensures: 

  • Precise embedding: High accuracy and repeatability for consistent quality. 

  • Efficient inductive heating: Contactless and energy-efficient heating for optimal results. 

  • Clean processing: No particle generation for safe and clean bonding. 

  • Global support: Our experienced team is available worldwide to help bring your projects to life. 

 

Optimize your production with EWS welding. 
Contact us today to learn more about how our innovative solutions can improve your manufacturing processes. 

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