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Technical Documents
Written by engineers, for design review
Weldability of Engineering Plastics
Joint design, horn selection and amplitude all assume the resin can be welded at all. This guide answers the question that comes first: can this resin be welded, and can it be welded to that one? Difficulty ratings for 26 engineering thermoplastics across welding, staking, insertion and spot welding, a compatibility matrix, and how glass fibre, flame retardants, pigments, regrind and mould release each move the needle.
- 26 resins rated across four assembly processes
- Compatibility matrix, with the one cross-family exception
- Filler thresholds, additives, moisture, near and far field
PDF · 0.5 MB · 12P
Plastic Staking Design Guide
Staking melts and reforms a plastic boss into a head that locks metal, PCBs or dissimilar plastics in place. Complete dimensional formulas for seven stake profiles, the boss diameter each one suits, and how boss, hole and tool cavity fit together. The geometry is identical for thermal and ultrasonic staking.
- Seven stake profiles with full dimensional formulas
- Boss-and-hole fit, and how to cut the tool cavity
- Heat, force and time, plus a troubleshooting table
PDF · 0.6 MB · 12P
Amplitude Reference Guide
Amplitude has the greatest influence of any welding parameter — interface heating scales with its square. Recommended amplitude bands for 24 engineering plastics at 15/20/30/40 kHz, plus how to configure the converter-booster-horn chain to reach the target.
- 24 materials across four frequencies
- Booster and horn gain combination chart
- Where to start, and how to read the symptoms
PDF · 0.6 MB · 12P
Horn Selection & Design Guide
The horn is the only made-to-order part in the stack. Covers how amplitude is multiplied through the converter-booster-horn chain, what each profile trades off, when slotting becomes mandatory, and which parts call for a special horn.
- 16-page edition with 30+ horn figures
- Amplitude chain and booster colour-gain table
- Fourteen special horns and a six-step selection flow
PDF · 2.4 MB · 16P
Energy Director & Joint Design Guide
A complete dimensional system for energy directors, shear joints, step and tongue-and-groove joints: director height W/8, 90°/60° included angle, 0.75W weld depth, and interference banded by part size — with the reasoning behind every value.
- 16-page edition, 24 sectional and 3D figures
- Dimensions and limits for eight joint types
- Design-review checklist and troubleshooting matrix
PDF · 3.3 MB · 16P
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