When assembling a part, some of the most important components to consider are the connections and joints. If the joints are weak, the whole structure will be weak. Heat Staking is the process of melting a boss from a plastic component into the hole of another component. The heating process can be accomplished using different ways such as hot air, ultrasonic system, or contact heating element.


Of the aforementioned options, heat staking is the one this article is dedicated to. It is a type of staking used in the plastics industry. Let’s dig a little deeper into that process to learn what it is and what is it used for.

Heat Staking:

The type of staking that involves melting a piece of plastic to hold two parts together in an assembly is called heat staking. During this process, the plastic boss is heated to a temperature where the boss melts and pressure is applied, then the boss is cooled down to form the bond. This process is low in cost compared to welding and other joint-making techniques. It can also be used in various industries because it offers the possibility of working on huge volumes in a cost-efficient manner.

Staking is a good solution to avoid vibrations and stress cracks. It can also be a way to avoid using additional hardware to prevent possible quality control issues due to defects. Even more so than other methods, it benefits manufacturers because the whole process of combining materials is finished in a single cycle time. This process uses the same base material throughout, has more pull strength, and doesn’t cause any mechanical stress. There are various methods of heat staking. To only name a few: hot tool staking, hot air staking, ultrasonic, and focused infrared energy.

The process of heat staking is used for various applications. It ranges from joining automobile panels to medical equipment to packaging, and more. In this blog post, we will turn the spotlight on two innovative heat Staking methods designed by Extol. The InfraStake and the Nanostake are, as mentioned, innovative technologies with the ability to stake in tight and delicate spaces.

The InfraStake

For this patent technology of heat staking, instead of a heating tip, infrared light is used to generate the heat. The InfraStake module is placed over the boss and its opening clamps the part to be staked. A concentrator is used to concentrate the heat only on the staking part. The IR bulb heats the boss radially and a punch performs a stake on the heated boss. To cool the part, airflow passes through the Infrastake module and then the punch retracts.


Here are a few benefits of InfraStake:

  • Safe for fragile components
  • Sturdy
  • High accuracy and repeatability
  • No smoke generation
  • High quality
  • High pull strength
  • Reduces stress joints
  • No surface damage
  • Mobile and modular
  • Low energy consumption
  • Changeable punch as per the requirements
  • Can be used in congested areas


This heat staking method is famous for its instant cooling effect. The staking rod cools down within a few seconds. This smart respond heating technology is also patented by Extol. The heating temperatures are regulated using low current value and increased efficiency. The current used is as low as 1.5A, making it easy for any connection.

The various benefits of this process are:

  • No plastic will get stuck
  • Can be used in congested areas
  • Easy connectivity
  • Low current-High performance
  • Comes with a LED indicator for real-time module status
  • The module remains cool even when the boss is heated

At DIY Robotics, we are collaborating with Extol and making a Robotic Heat staking Cell bundle, using the InfraStake technology. There are three models of InfraStake options depending on their stake dimensions: IS32, IS125, or ISM20.

Among the many heat staking and plastic staking technologies on the market, choosing the appropriate technology that can best serve your needs is quite a process. There are various factors that manufacturers need to consider before finalizing their choice. This is especially true when manufacturers want to adjust the staking process to their existing setup in order to save time and money. Manufacturers need to invest in the upcoming and latest technology that offers a short setup and installation time, high-quality machinery, and a quick ROI. One such solution is the DIY Robotics Heat Staking Cell with the Extol InfraStake heat staking module. Have a look at this new bundle and learn more about the InfraStake Technology.